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Date:  9-29-2013
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Cowl fitting & attachment

- The cowl has been VERY difficult to get on lately. The only thing that has changed is the oil cooler baffles, so I surmised they are too tight to the cowl. So I elongated the holes for the screws that attach the oil cooler assembly (including the baffles) to the engine. That allowed me to slide the assembly back about 1/4". To make that work I also had to trim the back edges of the aluminum baffles where they contacted the engine block. This really helped! The cowl goes on like it used to, on the right side. The left side is still a tad tight, so I may elongate the holes on that side of the oil cooler assmbly a little more.

- Then I located and drilled the holes for the countersunk machine screws that will hold the upper cowling to the fuselage. The floating nut plates are already installed, to I needed to get the holes in the fiberglass cowl. With the cowl off I drew lines on the masking tape that is on the windscreen, aligned with the holes. Then I measured the distance from the windscreen edge to the centerine of each hole and marked the tape (photos 1 & 2) with the measurement.

- Now with the cowl on extended the centerlines, and measured to the center of the holes. I pilot drilled a very small hole and verified that it did not hit anything on the other side, indicating I got the pilot hole somewhere over the nut plate. Then I enlarged the holes to full size for the screws, and verified the alignment by inserting the screws. They worked!

- I also did some more labeling inside the cockpit, including the MP3 jack, flap settings (in degrees), the brake and the flap handles, and the trim handle operation.
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Cowl at left; tape on windscreen at right. Tape marks made with cowl off.

Cowl at left; tape on windscreen at right. Tape marks made with cowl off.

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Another view showing 2 hole locations.

Another view showing 2 hole locations.

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