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Date:  1-17-2016
Number of Hours:  10.00
Manual Reference:  
Brief Description:  The cowling chronicle continues - 09

Weekend update. I glued 80 grit sandpaper on a 24" board to create a long sanding straight edge. Using it I sanded the top cowling along the firewall edge to create as straight an edge as I could get. That allowed me to set a consistent edge along the firewall (image two.) I now have a 1/4" gap at the top 1/3 of the spinner aft bulkhead and the cowling (image three.)

Due to the engine mount offset the engine sets at a slight angle, so the gap on the left side slide is a little worse than the right side. In image three the top of the spinner is 1/4" and the bottom is 3/8", so a little fiberglass lay up will be the fix. The other side at the bottom runs a little wider, may 7/16" so it will take a lot more work.

I also laid out all the Skybolt fasteners around the firewall. Fortunately there was a really good post on Vans AirForce and the Skybolt instructions were pretty clear. I have drilled the firewall top edge but I can not rivet those as I still need access through the top fuselage skin. I did drill and rivet both sides and the both edges of the firewall (see image one.) What takes the most amount of time is determining the "cut" line (the edge between the two cowls.) This impacts the spacing of the Skybolt fasteners running up the firewall. There is a line of fasteners that will connect the upper and lower cowling and the plan is to have that line align with one of the fasteners running up the firewall. If you look at image one you can see a portion of a flange just below the cowling edge at the firewall. That is the one that will line up with the other fasteners holding the two cowlings together.
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About a 0.020

About a 0.020" gap

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