Roll formed the bottom corners of the boot cowl sides, finished drilling the stiffeners, and trimmed the rear edges of boot cowl sides and bottom.
Comments:
* I was a little apprehensive about roll forming the lower side skins. The manual recommended a 1" diameter pipe, but all I had was a 1.25", and it seemed to work well. I tried a piece of scrap I had left over from a furnace duct project (available in a 2x3 foot sheet at lowes for about 9 bucks). I drew lines on the outside of the panel to show where the bend started and stopped, and also the center of the bend. I started the bend on the center line and just went slow bending a little at a time. A first the location of the pipe could be seen in my initial bends, but I made the following bends in between these areas and it all smoothed out. I was pretty happy (more elated actually) when it all fit together!
* I used a tin snips to trim the rear edge of the cowl pieces to be centered on the appropriate tube. I also trimmed the lower rear corners of the sides just above the landing gear so the tin along the bottom was centered on the longeron.
* The manual has you cut the stiffeners to length and drill at the welded tabs. Then the stiffener is removed and holes drilled at approximately 2" intervals and reinstalled. Then holes are then transfer drilled through the stiffeners and through the cowl pieces. There were a couple of holes that were not accessible from the inside, so to locate these holes I cleko'd the stiffener upside down to the outside of the cowl and transfer drilled the offending hole from the outside. This worked perfectly.
My roll forming set up.
Bottom needs to be trimmed to elliminate overhang past tube center.
Locating stiffener hole that is inaccessible from the inside.
