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Pauls Web Site
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Date: 1-2-2017
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Number of Hours: 5.00
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Manual Reference: NA
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Brief Description: Cowling Modifications 1
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I found that an easy way to make holes in the cowling without much dust is with a hammer and sharp chisel, on a sturdy table with some soft wood underneath.
Since I've putting the side cooling air exhaust vents on my Sonex-A model, as is standard on the Sonex-B model, I needed to figure out were to put the holes in the bottom of the cowling for the exhaust pipes. I got lucky on the passenger side, and the hole ended up in just the right place. The pilots side didn't go as smoothly, but it's not a big deal. It's on the bottom of the plane, and I can do some fiberglass repair.
As mentioned, the hammer and chisel method is a quick, clean way to make holes in the cowling. It's also a easy way to quickly make holes too big. As soon as I looked at the side exhaut vent I knew something wasn't right. It didn't have the elegant look of the factory Sonex-B model. Fortunately, while at Airventure this summer I had taken several pictures of the Sonex-B model, and was able to figure out what I had done wrong. This required more fiberglass repair.
I took the piece that I has cut out the the side, and trimmed off the required replacement piece with the band saw (which worked great). You can see the the third picture that the replacement piece is now fiberglassed in place, but needs to be files and sanded to it's final size.
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Left hole too big, Right hole good
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Ahhh, Hole too big!
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Fiberglassed hole smaller.
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