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Kurt Haller RV-9A
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Date: 7-15-2018
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Cowl hinge pin covers; fuel line leak check
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Spent the first part of today routing the backs of the hinge pin covers (with a Dremel end-mill like cutter) for a snug fit with extra thickness added to the back filling gaps around the periphery. I actuall too out the flange ahead of the front-most screws on the arrowheads.
Then it was time to sand the outer contour flush with the rest of the cowling. I made a "shield" from 0.020 aluminum to protect the cowl then sanded with 80 grit on a random orbit palm sander. (Image 1). This left a discenable lip around the edge, so I removed the metal shield and surrounded the cover with 3M electrical tape. Carefully block sanded until the tape was gently touched by the sandpaper all around. Did the same for the trapezoidal covers at the rear of the cowl. Just used 4 separate 0.020 strips as the shield for the machine sanding.
I brushed fresh epoxy on the external surfaces of the covers and laid down one layer of thin 2 oz 'glas, and topped it with peel-ply. Once cured, there should be a uniform, pinhole free surface ready for light sanding, priming, and gloss white paint.
I put some 1/2" pipe fittings, a ball valve, a pressure gauge, and an AN6 elbow together to test the fuel lines from wing root to the firewall bulkhead fitting. It's connected to the right tank's line in image 2, with 30 psi air feeding in. After closing the ball valve, no loss of pressure for 15-20 minutes seems good enough to me. All good on left side too. The fuel line to the mechanical pump was taken off and replaced with a plug cap for these tests. In image 3, the steel-to-steel AN fittings were torqued to 300 in-lb. This baby's ready for some gas, flushing, and flow test.
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"Arrowhead" hinge cover and sanding guard
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Fuel line pressure test fixture
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Engine side of the main fuel line torqued and marked
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