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Date:  5-7-2011
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Engine Cowl Rib

The upper cowl oil cans in flight; oil can today, cracks tomorow. Accordingly, I fabricated a rib out of .032 inch 2024-T3. Because the upper cowl is curved, and that curve is dependent on the firewall and nosebowl, it was necessary to make a pattern and then once the rib was made, to drill the rivet holes while the cowl was in place. I made a pattern using popsicle sticks glued to some left over shipping wood, and used fluting pliers to match the contour of the cowl. Because there's limited room, I put the rib immediately aft of the upper engine mounts. Prior to riveting, I alodined the rib and primed it with epoxy. The small, thin phenolic patch in Image 3 is adhesed there because there was some chaffing of the plenum onto the cowl. I'm not sure if the chaffing was from the oil canning or just tight fit, but the patch will protect the aluminium.
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Popsicle pattern.

Popsicle pattern.

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Fluted rib.

Fluted rib.

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Finished engine cowl rib.

Finished engine cowl rib.

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