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Alaska Sonex
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Date:  4-3-2011
Number of Hours:  7.00
Manual Reference:  SNX-P13
Brief Description:  Cowling 1

Began to fit the cowling (universal) to the airframe. Some minor cutting to start with. I had already made to wooden fixture at the prop hub which is used to screw through to hold the cowling with the proper propeller to cowling tolerance.

This process involves the taking on and off of the cowling parts approximately 2-3 million times. There have been frequent discussions regarding a common need to add material to make the fiberglass cowling fit. the company advises that this is not an issue and if the builder works with fit and removes material at the gear to fuselage cowling area the two halves will fit easily. Well I did that. Then I did some more. Then more. There is no contact whatsoever with the gear and if the cowling comes anyfurther back it would be pulled away from the prop hub. I ended up with just a slight gap on top but a major canyon on the bottom. I am going to do the horizontal split modification anyway but this is going to require some major additional glass. This can't be right.

I fabricated some sheet metal bands that will hold the cowling together while I glass the current split.

Placed the fuselage and cowling side hinges. Also placed the fuselage lower cowling hinges.

Trimmed the aft end of the cowling.
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The gap- midline topsides.

The gap- midline topsides.

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