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Kupe's Zodiac 650B
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Date:  7-28-2015
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Cowling Fit 5

Finished trimming the cowling today. There were still a couple places where the cowling was pushed up against the baffles so I removed the top cowling and sanded those spots down to the right size.

Next I began work on the nut plates that will hold the cowling pieces to the firewall area and to each other. There are two techniques for the nut plates. The first technique involves attaching a nutplate to the fiberglass cowling. The biggest difference from typical nut plate installation is countersinking the rivets instead of just dimpling as is done with a typical skin installation. For countersinking, I used a handheld 3/16" drill bit and finger-turned it to cut away a small layer of fiberglass around the rivet head side of the cowling.

The second technique is more routine - I used a dimpler on the rivet holes to make the rivet heads flush with the skin surface.
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Nut plate holes drilled into lower cowling using the nut plate as a guide.

Nut plate holes drilled into lower cowling using the nut plate as a guide.

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After drilling and countersinking using the hand-turned drill bit.

After drilling and countersinking using the hand-turned drill bit.

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Nut plate in place and riveted.

Nut plate in place and riveted.

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