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ONEX #54 Web Site
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Date: 6-12-2014
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Number of Hours: 4.00
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Manual Reference: P-02
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Brief Description: Modify cowling outlet per ONX-P02A
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Had two copies of ONX-P02 rev A made at Staples, one for the master drawing set and one to cutout the P02-11 lip pattern.
Bought some .025" aluminum sheet at Lowe's and used spay adhesive to attach the pattern to the stock. Pre-drilled #40 holes for the rivets, and #50 stop holes where the tab cuts will be. Cut out the aluminum and cut the tab slots. Used a file and sandpaper to finish the edges.
Made a 4-1/4"R semicircle with a CAD program, printed it and cut it out. Marked where it should go on the cowling and attached it with spray adhesive. Used a saber saw with a fiberglass blade to enlarge the cowling hole per the plan. Finished the edges with a file and sandpaper.
Starting at the front center, with the rear held with clamps, I drilled and #40 cleco'd the lip to the cowling. Worked my way from front to rear, alternating sides, pushing the lip against the cowling and drilled/cleco'd the remaing holes. Updrilled to #30, disassembled and deburred. I had to do some minor trimming at the back of the lip to match the original fiberglass cut and make sure I had clearance to install/remove the lower cowling pins.
Applied fiberglass resin to all the edges of the upper and lower cowling to seal them from the elements, oil. gas, etc.
I wasn't happy with the baffle seal I had on the left side of the engine, so I remade that.
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Cowling lip P02-11
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Template for semicircle
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P02-11 lip installed
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