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BOB'S WEB SITE
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Date: 8-29-2020
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Number of Hours: 3.00
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Manual Reference: Section 37
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Brief Description: Drilled cowling side hinges
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It's been a few days without a dizzy spell (knock on wood) so I felt comfortable taking on the task of drilling the horizontal side hinges to the top cowling.
I taped the two cowling halves together after rechecking the fit, Then drilled one at a time, alternating side to side, attempting to keep a 1/32" gap, which, for the most part, I have with the exception of a few places where it's 1/16" and a few places where I need to sand a little bit to open up the gap.
I was very pleased with how it's come out so far. The exception on the rear corners where the top and bottom meet. There's nothing to support the top cowling in that spot. And the hinge pin tends to push the top cowling out a little bit. So when drilling, I pulled the pin out slightly. I could probably cut the pin size down, or try to bend it into the curve a little bit, which, unfortunately, also might make it more difficult to put it in. I'll see what other people do.
The front right part where the hinge pin tab is needs work. I took out too much on the corner so I'll be putting a little fiberglass back.
Then I drilled the six holes in the front out to full size -- #19. Before putting nutplates in, I'm going to reinforce that area with a little more fiberglass.
Then I took the top and bottom off, marked all the hinges, and deburred all the holes in all hinges.
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The troublesome corner
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Need to work on the corner
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All in all, a really nice, tight fit.
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