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Zenith CruZer & Sonex Logs
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Date: 2-23-2012
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Number of Hours: 2.00
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Manual Reference: n/a
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Brief Description: Temp Floor / Cowl Work
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When I was initally building my fuselage, I used a plank of wood across the floor pieces to sit/stand on during construction, fitting the tank, etc.
Well, now that I've populated the under-seat area, the wood will no longer fit. main offenders are the "hat" section over the center elevator pushrod, and the elevator idler pivot in front of the aft spar. I thought for a bit on how to build-up the floor so the plank could be used. It would have been hard to find 4.75" tall pieces of wood; I could get a 6x6" timber and cut down sections, but that would have been bulky. I'd be concerned about building-up a stack of 2x4's thinking that with any shift in the floor, they might tip over.
Then it occured to me that 4" diameter drain-waste-vent pipe would be ideal. The normal DWV pipe is about $20 for a 10' section at Lowes; more than I needed, and more than I wanted to spend. Then, as I was leaving, I saw a display with 2' lengths of "non-pressure" foam core pipe. Perfect! Has great longintudinal rigidity, and there was enough that I could get 5 pieces out of one piece.
So, pic1 below shows the cut pieces in place on the cockpit floor, and pic 2 shows it with the floor in place.
Next, I polished the left side of the cowl after buffing it a day or so ago. This was the first re-fit of the cowl after I had installed the baffle seals. Let's just say that the cowl is STILL not fully installed. I'm going to have to trim-back some of the baffle seal, but the hard part is that this is not the "normal" red silicone baffle stuff. This is a "P" section rubber seal as supplied by Sonex. I've been able to get the side and top hinge pins in, but have only been able to get about 6" of the lower hinge in. I even had a helper push on the cowl in order to get the lower pin in, but it was a bear to do. Finally ran out of time so will see what tomorrow brings. I've got to get it loose enough that I can get it on by myself if I had to do so.
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