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Zenith CruZer & Sonex Logs
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Date: 3-23-2011
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Number of Hours: 1.20
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Manual Reference: SNX-P13
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Brief Description: Cowl Fitting, Day 2
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Whereas yesterday I was quite upset that I could not figure out where to cut or adjust to get the cowl to fit, today everything just basically fell into place.
Reference pic 1 below. About 1/3 of the way up from the bottom of the fuselage, you can see some blue sharpie marks on the aluminum. These represent 1" from the fwd edge of the fuselage skin. Also note the bottom edge of the fuse where the cowl meets the fuselage.
Sonex says that "most" cowls end up being trimmed almost an inch along the cowl-to-fuse line referenced by the blue marks. This is close to being just over 3/4", which is pretty good. The second standard is the bottom edge. If enough material is not removed from the back edge of the cowl, the cowl will hang down below the fuselage line. This looks just about perfectly flush.
An added issue with this is that some builders have not trimmed enough off the side pieces. As a result, for some reason unknown to me, that creates a gap between the cowl halves on the lower seam - these builders then have to build-up a fiberglass patch to straddle the halves. Yesterday, the gap was there. Today, the gap is gone (well, I haven't fit the left side, but it was VERY obvious the cowl half was off-center from the engine yesterday).
What solved it all? I had not trimmed around the gear leg enough last night. I think I removed about another inch of material around the gear leg tonight, and things just slid into position.
Next up is to mark the cowling for trimming the aft edge so it fits well against the fuselage.
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