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Date:  1-29-2019
Number of Hours:  20.00
Manual Reference:  
Brief Description:  Install the prop

Before the cowl can be installed, I need to have the prop and spinner in place.

The pre-assembly of the spinner bulkheads was completed and they were installed on the prop.

For the spinner install the prop has to be cycled to get the cutouts properly sized. I did the flat pitch cut outs with the prop on the bench by making cardboard templates, then lots of fitting, filing, fitting etc., TO complete the cut outs I needed to cycle the pitch to course. I could only cycle the prop with it bolted down. The easiest location to bolt it down without having to fabricate a temp mount was the front of the airplane.

Once on the plane I used a padded, slotted board to pull the prop to course pitch, tied it off with a rope, and completed the cut outs. I marked and drilled the screw holes once the cutouts were completed.

Next, I made templates for the fillers behind the blades out of cardboard first, then aluminum. I used the cut outs from the instrument panel PFD for the correct thickness stock. Getting the fit just right was a long process of fitting, cycle the prop, file and repeat. Once done they were riveted in place.

The prop now came back off. Everything was disassembled and the nut plates installed. The rear face of the spinner was trimmed and all was reassembled. Reinstalling to the airplane was a fun exercise as I didn’t realize the prop was clocked to the engine by a boss/recess on two of the bolts. After tightening for about 20 mins, I realized my mistake, took it back off, rotated one hole and started the tightening process all over.

For those that have never installed a CS prop on a 540, each bolt has to be turned in sequence about one turn at a time. The wrench will only get a single facet before resetting. It takes a long time. I need to but a special tool from Hartzel to torque the prop. Standard crow’s feet don't have the reach.
While that tool gets ordered, on to the cowl
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Fitting the close outs to the prop

Fitting the close outs to the prop

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final install of the bulkheads

final install of the bulkheads

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