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Jean RV6 Construction Log

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Date: 5-24-2024
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Number of Hours: 3.00
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Manual Reference:
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Brief Description: Making space for the alternator fan
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There was an irritant that I had to clear off my head. When using the proper belt and tensioning it, the fan in the front end of the alternator had only a 1/8" clearance. I bought a belt that was 1" shorter, because there was nothing in between and I could not put it on. It was too short. And I also know that once the engine starts, the vibration will make the alternator fan and the cowling kiss ! I think this happens because I am using a 360 engine instead of a 320.
I had to provide more clearance. So, I cut the cowling at the proper location on 3 sides and then heat the left uncut side to reform it so it provides an additional 1/4" to 3/8" clearance under the alternator fan.
Then I fiberglass that new shape from the outside first, then from the inside and finally I made an epoxy fairing filler microballoons for the finishing side. I still need to sand it but at least it is done. It has a nice enough shape and I think once sanded , it will be perfect. The good thing is the clearance under the fan is far more than sufficient.
One other frustration I experienced was when I tried to form one of the pitot tubes for the AN fitting, it splitted open. I redid it 3 times to realise after getting the same result that there was a defect in the tube . My usual luck ! I wrote to Dynon who after reviewing my pictures will send a replacement heated pitot tube for 0$ ! All this done via email . One thing they asked was to insure that the pitot tubes and wiring was cut to the base. I did that and sent them the pictures. Great place to deal with, comprehensive, friendly ! Just positive interaction with Dynon since day one !
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Cut , folded & fiberglassed
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Not good angle to see the difference
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Finish before sanding
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