I began by removing the piano hinges on the lower portion of the firewall, Spoke with a builder who had his break on his RV-6 and it recalled stories I read of others who have had the same outcome. So.... I drilled them off and fabed some .062 and match drilled it. On the right side, I need all of the room I can get, I replaced the .020 shim w/ .040 if it moves the fiberglass too much, it will be easier to fair that than the other way around. I'm going to install 3 countersunk #8 nutplates on each 'lip' I'll use ss screws with ss countersunk washers to keep everything tight. Then on to fitting.... I had to lower cowl on and off the fuse another 20-25 times today. Forcing my self to go slow and try and think through each situation before sanding. Also try an limit the number of sanding/changes per fit cycle as sometimes a little material taken off in one place will make a WHOLE LOT of difference in another. The GOOD news is that it looks like the 'skimpy' right side is going to work out. The low spot is now just flush with the upper cowl. I've still got some fitting to do at the front around the spinner, the top and bottom fit flush with the spacers that I taped to the backplate, but the lower cowl spinner ring seems to have a slight tilt aft when viewed from the side. Not sure how this could be rectified, as the bottom rear of the cowls are now flush with the fuse and the only way to get the front spinner ring flush would be to raise rear of the cowl while keeping front stationary. No way to do that.
Replaced piano hinge with .062 alum plate and countersunk nutplates
it's getting close but no cigar .... yet
Here's the side that has been the source of all the concern. Lokks like I'm out of the woods
