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Marlins Web Site
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Date: 8-23-2023
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Number of Hours: 18.00
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Manual Reference: N/A
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Brief Description: Lower Cowl Heat Shield Installation
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I studied several builders heat shield installations and came up with a design that will insure the lower cowl is protected from the extreme exhaust pipe heat. I tried using paper to make templates, but the interior cowling curves make massive wrinkles in the paper and won’t work. Plan “B”; use paper towels and cheap masking tape. I took the better part of an entire day to create these templates but there is still a problem. The paper towel/taped templates have perfect, conforming curves but they won’t lay flat on the aluminum heat-shield material to get an accurate template; just like the paper templates did. Solution…call in my wife who does a lot of sewing and ask her to “fix” my paper towel templates. It took another three hours for both of us to make adjustments for curved, budges in the paper towel templates, but she magically did it! Next, I laid out the “new and significantly improved” paper towel templates on the heat shield material, drew an outline of the templates onto the sticky-back aluminum stuff I bought from Aircraft Spruce. I easily cut the final pieces with a scissors but now I had significant problem #2. Aircraft Spruce, or the sticky-backed aluminum manufacturer, shipped the aluminum rolled up make permanent, massive winkles. My wife and I spent five more hours attempting to work the wrinkles out of the aluminum sheeting (about 3x the thickness of aluminum foil); knowing full-well that more wrinkles will be created when you apply this stuff to a curved cowling. It took three more hours to mask, spray adhesive, and apply the heat shield. It’s on now and it looks OK, but I’m sure there must be a better way to apply these heat shields.
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Paper Towel Templates
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Marking/Cutting Heat Shield
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Heat Shield Applied & Smoothed
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