Clecoed the hinges back into place on the aft of cowls to prevent the counter sink from enlarging the rivet holes in the fiberglass. Machine counter sank the rivet holes for the hinges. Riveted the hinges to the sides and top of the cowls.
Started to re-install the cowls in order to measure and trim the sides, however found that I could not install all of the hinge pins. Initially installed the top cowl hinge pins from the bottom up, with considerable difficulty. Then installed the bottom cowl and attempted to install the side hinge pins from the top but could not get the pins in with the small gap between the upper and lower cowls.
After reviewing the plans again, decided that the only realistic way to re-attach both cowls at the same time was to jump ahead in the plans to Page 47-7 and fabricate/install the top cowl hinge F-1001Y Cowl Upper Pin Retainer and F-1001Z Filler Plate. In trimming the back of the top cowl to accept the Pin Retainer, found that the ends of the top hinges interfered with the retainer. Had to trim back both of the top hinges to allow the retainer to fit. Used the Dremel tool with diamond cutting disk to cut the hinge barrels back, and then filed them back further until the gap between them was wide enough for the retainer. Then had to trim back the hinge mounting flanges to allow the retainer to sit flush against the fiberglass cowl. Again used the diamond wheel to cut mostlly through the hinge flange, then used a screw driver to bend the flange tab up and down a couple of times until it broke at the cut line. Used files to clean up and debur the edges.
After cutting one new hinge rod to replace a badly bent rod for one top hinge side, I was able to install the bottom cowl with side hinge pins pushed into place from the open top with little effort, then installed the top cowl and inserted the pins from the center opening cut for the pin retainer, also with little effort.
Drilled rivet holes for the new short bottom hinges and inserted clecoes after the cowls were sec
