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Zenith CruZer & Sonex Logs
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Date:  7-16-2022
Number of Hours:  2.70
Manual Reference:  n/a
Brief Description:  IInitial fitment lower cowl

Taped the two cowl halves together; A bit spring-y. Used some pinch clamps to hold things while I applied the tape. Cowl halves fit quite well together. Zenith docs expressed a concern to ensure the joints were tight, but I guess that was for earlier years' production.

Slid the cowl into position and got things squared up. Took a LOT of measurements to determine how much 'glas to trim fromt he lower cowl. I already trimmed initally on the upper cowl, but nothing on the bottom. Used tape to mark the position of the aft edge of the cowl so I could determine how much to trim off the fiberglass to gee me a 1.5" flange.

It's obvious I will need to trim some of the fiberglas around the air filter inlet since the prop flange is a bit recessed on the lower edge, The cowl already sits as far aft as it will go since the 'glas is right up firm on the air filter element.

Removed the cowl and turned upside down on th e sawhorses. Using measurments from the tape lines, I marked the cowl for cutting the first trim on the lower cowl, and second trim ont he upper. I also marked screw locations for the upper/lower mating line. These will use nutplates and AN machines screws.
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upside down to sit on sawhorse

upside down to sit on sawhorse

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