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Building Integrity
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Date:  9-29-2014
Number of Hours:  5.00
Manual Reference:  Section 2
Brief Description:  Micro sanded Z-grip added.

The day began with the realization that I had Left my DA Sander at home. DOH~ The next 2 hours of block sanding was a real waste of time. At lunch I decided to go back home and get it. After coming back it took all of 10 minutes to sand down the micro with the DA. note to self, don't forget the tools for the job again. I then prepped the surface for a good thick layer of Z-Grip. Taking the advise given by Joe Coraggio, I'm going to basically be turning this into a male mold and covering it in turtle wax before laying up 2 plies of Carbon BID. The big plus here is that I will have a MUCH lighter cowling that will only need minor fill work for a nice perfect contour and it's only a day or 2 more in prep work than if I went ahead without it. Plus I'm convinced that when all is said and done, this will actually be the fastest way to get this cowling done.
It's really weird to see how TALL the cheeks are on the cowling but I have to remind myslef that the UL engine is built taller than a Lyc. PLUS it's 4" narrower so it intensifies the look. The pictures don't represent its curves at all though. In person I'm in love with the shape.
On a side note, I took a piece of foam board and taped it on the underside of the belly all the way to the oil cooler to visualize a possible lower cowling contour and I actually like it a LOT more than I thought I would. I was worried that the bottom would be a huge compromise in looks, but so far I think it may work out really really well. I'm gonna try ending the bottom right behind the oil cooler so that the rows are in the open air. My "guess" is that the air passing around the cooler will "pull" the hot air away from the cooler. My only concern will be massive turbulence going into the prop. I'm sure this will need some work, but the cooler will see cool air for version 1.
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micro sanded down

micro sanded down

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Z-Grip all over and thick!

Z-Grip all over and thick!

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possible lower cowl contour

possible lower cowl contour

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