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Zenith CruZer & Sonex Logs
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Date: 3-27-2011
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Number of Hours: 3.50
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Manual Reference: SNX-P13
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Brief Description: Cowling Trim, Hinge Fab, Xpndr BNC
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Obtained BNC connections; the transponder cable from the factory only had one end crimped on it, because they have no way of knowing how long the cable needs to be. Stripped cable end and crimped terminal to it. Re-installed in airframe.
Spent some time re-finessing the fit of the cowling against the prop hub and windshield bow. When I was finally happy, I marked a trim line on the fuselage side. Removed the cowl, then transfered the measurements of the trim line onto the cowl. It is not the same distance top-to-bottom. Using a cutoff wheel in my dremel tool, cut off the aft side of the cowl side piece. Have not trimmed the windshield bow line yet because the windshield is not installed and I want a good fit.
Used a vixen file and sandpaper wrapped around a piece of scrap channel stock to smooth the cut line straight and smooth. Test-fit the cowl. A bit more needed to come off at the bottom, so removed the cowl and filed some more. Put back in position. Nice fit - no gaps along the mate line.
I'm a bit concerned about the centerline placement of the cowl half. I've got the cowl trimmed back about as far as it will go, as per instructions, but the lower centerline of the cowl may be just a hair shy of the centerline as measured on the air filter. Then again, the air filter may not be 100% dead-centerl. I'm talking less than 1/16" gap here. Tomorrow I'll run a sight-line to see where things line up.
Lastly, I measured, cut, and pilot drilled the side hinge halves for holding the cowling to the fuselage. Also cut and bent the hinge pins.
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