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Brad Wilkinson, Bearhawk #1062
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Date:  3-1-2009
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Boot Cowl, Top Section

Cut the top Boot Cowl section to fit around the cabane vee tubes. This is the piece between the firewall and the instrument panel at the top.

I decided to just cut the panel to fit around the tubes, instead of making elaborate pieces to fit around them that are easy to remove. Although this panel is removable - I really don't plan on removing it for a very long time once the airplane is finished. So I don't need this to be all that easy to do.

I just cut slots at the front and oval holes to clear the tubes. I spent a lot of time measuring and marking, and actually measured the angle between the tubes and the panel to calculate the shape of the oval accurately. I laid this out on cardboard first, and cut it out. I did mess up the first pattern with a boneheaded layout measurement mistake, but I got the second pattern laid out correctly. I realized it as soon as I cut it out and looked at it. I know that nobody would believe it, but the second one actually fit great the first try! One of the benefits of being an engineer I guess.

Once I transferred the pattern to the panel and cut it out, I just had to do a little filing of the holes to get the clearance that I wanted. Otherwise it worked great.
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Cardboard pattern (with calc's)

Cardboard pattern (with calc's)

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Clean fit of the top panel

Clean fit of the top panel

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View from below

View from below

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