Cowling Fittment

In this update, we begin fitting the cowling. 

Rough fitting of the cowling top to bottom . The top and bottom have been cut to the scribe lines , this gets the close to final fit . The mating edges are now sanded removing small amounts of material to get to the finish fit . This process requires a lot of assemble , mark , sand, reassemble and so on. Only small adjustments are made here ( aim small - miss small )

 Fitting the cowling to fuselage . Same process as above make small adjustments as you go . The cowling will come off and back on many times before you get the fit you want . The space behind the back spinner bulkhead is 1/8 at the top 3/16 center and 1/4 at the bottom , this gap will even out during the first 100 hrs of operation as the engine settles in the mounts .

 The rivet locations are transferred from the fuselage to the cowling and #40 holes are drilled in the fiberglass . Holes are then drilled into the underneath hinges . Parts are then dissembled countersunk and a coat to epoxy applied to the inner cowling surfaces . 

All hinges are riveted to cowling

Rear window and cowling fitting

Rear Window installation

Rear Window installation

 Install upgraded brake lines

 Install upgraded brake lines

 Install 

2 1/8 spacers and back spinner bulkhead to simulate prop install for cowling fitting

 Install 2.1/8 spacers and back spinner bulkhead to simulate prop install for cowling fitting

Sanding fitting cutting and more sanding fiberglass cowling

Sanding fitting cutting and more sanding fiberglass cowling

Sanding fitting cutting and more sanding fiberglass cowling

                     Sanding fitting cutting and more sanding fiberglass cowling

Engine hung

This post again is not a full weekly update like normal, it is too good not to share.  The engine is now attached to the airframe!  We hung this brand new Lycoming IO-390 attached to the mount, being inspected by Johnny.  

Fiberglass and Landing gear

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Full update of last weeks work.  More fiberglass for the canopy and landing gear installed. 

More fiberglass layers and filler and a lot of sanding

 Fitting the tail wheel spring and wheel

 This process required quite a bit of hand fitting with 400 grit emery cloth . This is a very tight machine fit . 

 Fitting the tail wheel spring and wheel

Fitting and installing the gear legs to engine mount, nice fit

Fabricate and install the soft aluminum brake lines from the firewall the calipers . I installed these per the plans and I'm not liking this setup . These lines will be replaced next week with Aeroquip 303 flexible hose and 491 fittings . The cheap aluminum tubing may be ok but it may not . I have repaired other aircraft where the alum tubing  cracked and broke due to flexing . Not worth taking a chance IMHO . 

Nice legs!

Here is a quick pic from today.  The RV has legs!