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Marlins Web Site
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Date: 3-10-2022
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Number of Hours: 5.00
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Manual Reference: Sec 12, DWG 45
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Brief Description: Cut/Fit Lower Cowling
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Cutting and fitting the lower cowling to the upper is a challenge. After making the initial cuts, the process of sanding/adjusting/marking/sanding is much easier if you sand the cowling in-place. I duct-taped the upper cowling and the fuselage, the, pulled the lower cowling outward and sanded in-place whenever possible. This process sure beats removing the entire cowling, then reinstalling after doing a small bit of sanding 25 or more times until you get a good fit. At first, even before the initial cuts were made, it didn’t look as though there was enough material and I would have to do massive amounts of fiberglass rebuild. After reading several other guys blogs, I finally realized how the process of fitting is done. In areas that don’t fit, you have to sand a very small amount and then see what changed on the opposite side of the cowling. Doing this repeatedly and only sanding a very small amount each time, you can actually get something that looked impossible to fit together fairly nicely. You can see from the pictures below what I had to start with.
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Left side huge gap to start
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Left front seemed good
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What caused gap on left side
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