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Home of the Spodplane
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Date: 1-29-2024
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Number of Hours: 2.00
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Manual Reference: 23-16
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Brief Description: Lower cowling baffles. Oil check door replacement
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Make templates from the full size ones in the plans and try fit them to the cowling. Result is hilarious! The templates are not symmetrical, and either is the cowling. Looking at the pictures and a few other builders I gather the side baffles tops are supposed to make a straight line from the NACA opening to the edge of the boat bit of the trailing edge of the cowl, with the sloping baffle betwixt. I discount a bit of the leading edge for my diffuser and cut out cores from 1/4" H100. Fart around with the result until they fit reasonably well, prep the foam and layup 1 x BID on each side with peel ply and weight for cure.
I have resin left over, so extend the port trailing edge of the cowl on the inside, to see if I can retrieve a better join line with the top cowl. 2 x BID onto a bit of plastic hot glued to the underside.
Drill out the oil check door rivets and hot glue it to a wood form that flexs it a smidge, so it won't bulge under the opening spring tension. 4 x BID over that, with peel ply on both sides.
Drilled out the other half of the oil check door hinge, drilled 2 x 3/16" holes, taped it up, inserted clickbonds and floxed them onto the inside of the cowl, clamped with cleco through the original rivet holes.
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Something like that. Probably.
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Oil check door replacement
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