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Thread: First, Build a Shed

  1. #411
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    Thanks Eddie. I wasn't quite sure what specific tape that was but I know it now that you've explained.
    Carl Strange
    Building
    SS7, 912iS, Oratex, G3X

  2. #412
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    The original "prop hub" circle was a mess and no amount of filling and filing was going to make it pretty. So a foam board template was cut that was wide enough to clean up the ragged edges, a circle drawn, and a Dremel with cut-off wheel quickly made a nice clean hole. After a couple of failed attempts to hold the lower cowling in just the right spot - eyeballing the prop hub clearance while my wife taped, it occurred to us that the foam board template could serve as a position locator if we cut a doughnut hole and slipped it around the prop hub. That locator, and the 7/8" sticks taped to the hub, made it a snap to position the lower cowling. That done, the upper cowling slipped neatly into place. Say, that wasn't so bad...

    Note, with all of the excellent ideas posted on the forum, I wouldn't be at all surprised that I picked this idea up from another thread. Happily, the thought was there when needed.
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    Carl Strange
    Building
    SS7, 912iS, Oratex, G3X

  3. #413
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    Default Re: First, Build a Shed

    Everything youíve said here Carl resonates. The amount of tweaking, pushing, adjusting, filling in blemishes, and especially the aligning of the cowl with the prop hub and making sure it wasnít cocked over at some weird angle ..... that all took days to sort out. The next big step will be fitting the cam locks. Strongly recommend you firmly secure the cowl to itís final position and then pilot drill. I didnít do that and found that I had to drag some holes to get everything to line up. Also, I found the inner angles that hold the camloc receptacles at the firewall are very flexible so when I Pilot drilled them, they bent inwards. After Iíd attached the receptacles I had to drag holes in the cowl to align. So suggest you donít full size holes until you know everything aligns. Temporary restraining of those flexible firewall @ngles will help a lot if you can do it.
    David
    SS7 Builder

  4. #414
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    Thanks for the tips David. My latest "whoops" was realizing the lower cowl piece wasn't fitted snugly to the bottom of the boot cowl. We had penciled in some measurement on the sides of the boot cowl, showing distance from the center point at the top. These marks helped us center the lower cowl so it would be "level" rather than twisted. When it came time to mark the upper cowl for trimming, we noticed the back of the upper cowling didn't have sufficient overlap of the bottom cowl. It took a minute to realize we worried too much about the lower cowl being level and hadn't thought to neatly fit the lower cowl to the boot cowl.

    Now that we've made that adjustment, there is another oddity to deal with. The boot cowl seems centered since the lower curves fit snugly against the frame. The lower cowl is hanging so it's lower curves mate nicely to the bottom of the boot cowl. The upper cowl can be positioned to fit neatly with enough overlap to trim. However, the mark we made at the middle rear of the upper cowl is about 1/2" off from the center of the boot cowl. This will require some head scratching and slight adjustments.

    Once the cowling is complete and all buttoned up, is there any problem with the front of the cowling sagging down over time? What keeps the front of the cowling in position? Just the ring of camlocks on the boot cowl?
    Carl Strange
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    SS7, 912iS, Oratex, G3X

  5. #415
    Senior Member jiott's Avatar
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    Default Re: First, Build a Shed

    Carl, I have found that the cowl does not sag over time. The 3 pieces of cowling all camlocked together form a very rigid structure.
    Jim Ott
    Portland, OR
    Kitfox SS7 flying
    Rotax 912ULS

  6. #416
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    Default Re: First, Build a Shed

    Quote Originally Posted by jiott View Post
    Carl, I have found that the cowl does not sag over time. The 3 pieces of cowling all camlocked together form a very rigid structure.
    Concur with Jim. Given that there's a bit of slack in each camloc, I too was worried about it. But once all those camlocs are done up, the cowl structure is very rigid, surprisingly so.
    David
    SS7 Builder

  7. #417
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    Thanks for the feedback guys.
    Carl Strange
    Building
    SS7, 912iS, Oratex, G3X

  8. #418
    Senior Member efwd's Avatar
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    Default Re: First, Build a Shed

    I have a slightly different experience. I can button mine up looking perfect at the nose cone, then walk up front , pull with a couple pounds force and cause my cowl to dip about 1/4. I mention this because I may know the culprit here. "Her" it goes (with geographic accent}. When you drill the camloc holes you will recognize that there is a step in the outer diameter of the Male half. If I wanted my recessed fastener to lie flat, then I had to slightly enlarge the holes in the fiberglass to accept the step. So be careful how you address that issue should you come across that as well.
    Eddie Forward
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    SS7, 912iS, Garmin G3X

  9. #419
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    The upper and lower cowling pieces are trimmed and sanded. Using strapping tape, as instructed in the manual, worked nicely for securing the pieces in place. I may have the pieces fitting too snugly in places and might do a bit more sanding before installing the camlocks. There will necessarily be some filling and sanding where the front of the cowl pieces mate but I'm pretty happy with the fit at this point. My wife will be very happy to have this part of the project complete. Can't imagine doing this part of the build without her to help hold and tape.

    This evening I've been perusing threads, looking for ideas on the camlock installation. Months back, someone suggested creating gasket, using the high temp silicon, to seal the gaps between the firewall and boot cowl. The idea was to use plastic wrap as a release agent on the boot cowl surface. Any thoughts on the thickness of this gasket causing problems with the camlock installation?
    Carl Strange
    Building
    SS7, 912iS, Oratex, G3X

  10. #420
    Senior Member Cherrybark's Avatar
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    Default Re: First, Build a Shed

    I reviewed Tropical Tuba's pictures were he was working on his cowling. I'm almost embarrassed to admit it hadn't occurred to me that, once secured with clecos, the upper and lower cowl pieces can be worked on as a single unit off the plane. This makes the faring process much simpler. For some reason, I was thinking of working on the individual pieces - only bringing them together to check on the fit.

    There are times where these forums have really saved me from wandering off into the weeds...
    Carl Strange
    Building
    SS7, 912iS, Oratex, G3X

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