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Date:  1-25-2011
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Cowling

Removed peel ply from yesterdays layup.
Rough cut door shape through cowling leaving 4 tiny tabs to hold the door in place.
Applied plastic release tape over door area. Used exacto knife to trim tape around door outline. Removed tape from all areas outside the door leaving only the door released.
Layed up 5 bid carbon extending 1" beyond door in all directions. This will become the flange against which the door closes.

After flange bid cured, drilled 4 holes through door and flange.
Carefully cut the 4 small tabs connecting the door to the cowling with a dremel cutting wheel.
Popped door free from flange.
Cut 4 small strips of previously cured 4 bid carbon. Mounted #6 nutplates to strips and bonded the strips to the flange with epoxy/flox.
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door cut out except for tabs

door cut out except for tabs

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nutplates mounted

nutplates mounted

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door exterior

door exterior

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