4.2.6 Cowl

The manual tells us to carefull cut on the pre-marked line in 6” segments. We then are to use tongue depressors and a hot glue gun to help support the cowling as it gets cut away. Additionally, the flange is not to be cut until we’re ready to remove the lower cowling. I was dubious that these large “popsicle sticks” would actually hold everything together. But they did!!!

Fuselage - Lower Cowling Removal (1)

This is one of those big, scary cuts we need to do on this project, removing the lower cowling piece from the fuselage!

Fuselage - Cowling Removal (1)

A look at the cut from the inside. The popsicle sticks temporarily hold the cowling in place during the cut!

Fuselage - Lower Cowling Removed! (1)

Earlier you saw the cut lines for the lower cowling. Here, the cowling is now removed. I needed to do a bit of sanding and straightening where the cut was made.

Before the lower cowling is removed, a flange needs to be created to be used for attaching the cowling back onto the fuselage. That’s literally done with duct tape and a few fiberglass layups. The duct tape is used to help separate the flanges from the fuselage once the epoxy is dry. Epoxy and fiberglass does not stick to the plastic-like surface of the duct tape.

Fuselage - Lower Cowling Section (1)

Before removing the lower cowling, a flange needs to be created out of BID and epoxy. The flange is used to reconnect the lower cowling to the fuselage proper. Here I am straightening and sanding the flange.

And here’s the lower cowling clamped to my worktable for finishing off those edges of the flange.

Fuselage - Lower Cowling (1)

Here's a shot of the lower cowling piece temporarily clamped to my worktable so that I can straighten and sand the flange.

Naturally I need to test to make sure that I can put the cowling back on. In the photo below I’m using some clecos to temporarily hold everything in place.

Fuselage - Lower Cowling Reattached (1)

What comes off goes back on. In this photo the lower cowling is reattached to the fuselage to check for fit.

Many builders are doing a modification that creates a sleeker aircraft by eliminating all of the external bumps created by the screws used to hold the cowling to the fuselage. Another flange needs to be created that the lower cowling slips into. Some internal brackets are also added that lock the cowling into place. I’ve started that procedure but haven’t finished it yet. When it’s done I’ll add those photos to this page.

There’s still more to do though, including installing the battery shelf and landing light. Click here for the battery shelf installation.

ui© John Trautschold 2018