Brief Description: Throttle Body Install & Cowl Pin Cover Plates
Completed the cowl cover plates install:
With the fiberglass installed yesterday now cured, had to remove the cover plates and cut the fiberglass along the cowl split lines. Tried to cut the fiberglass from inside, but could not get the dremel tool with diamond disk into the front half of the fiberglass due to the narrow space. Cut the line as far as I could from inside. Cut the fiberglass split line from outside up to the ends of the cover plates. Was not sure how to proceed from here! After searching the tools at Home Depot during lunch, decided to purchase and try using a hooked knife blade (roofing shingle blade) in my Stanley retractable razor knfe to try to cut the fiberglass from inside. While this didn't work, I found that by inserting the hooked knife blade into the cut just in front of the cover plate and then rocking it forward, the hooked tip of the blade pushed against the back of the cover plate and popped it out of the cowl. This now allowed me to cut the split line from outside with my diamond disk.
Layed out a larger slot similar to the one shown in the Aerosport instructions, drilled holes at the end of the slot layout, and cut between the holes with the diamond cutting disk to form the slots. Cleaned up the slots with sand paper. Installed the nut plates on either side of the slots for the screws that will hold the covers in place.
Installed the throttle body to the engine: Could not find instructions regarding the installation of the throttle body to the engine. The installation instructions from Lycoming don't address this, nor do the Van's construction drawings. Removed the cover plate from the engine and cleaned out the preservative oil as best I could with paper towels and rags. Installed the throttle body using the nuts and lock washers that were holding the cover in place, but none of the flat washers. Torqued the nuts to 110 in-lbs using a crow foot. Hooked up the fuel hoses per the Van's drawings connecting the throttle body to the fuel pump and the fuel pump
