Constructing the cowl
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(click picture for larger view)
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Plans & Book Aft Fuse & start Center Section
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Top
Row
Photo #1 - This is the way I decided to start. Am sure there are better ways to do most everything but this is the way I am starting and tomorrow may rip it all off and have another idea. The most important thing to me, for a cowl, is to have pleasing lines that conform to the lines of the fuselage. After I am satisfied with that I will then worry about cooling and getting everything to fit. First I made three wooden templates - Upper and lower that establish the side view lines and the nose bowl piece to match a 9 inch spinner. Next I needed some kind of visual reference about mid way so I installed a 1.5" thick foam former directly behind the right cylinder. Next I will just fill it all in with various foam pieces and sand to the formers. At least that is today's plan. I already have discovered two problems. The Cub type eyebrows I have, may not work so may make my own. Second, the Taylorcraft type exhausts I have, tuck too tightly to my cowl so am hoping they can be heated and re-bent. A few years ago I was informed that 'we' don't have problems ........ 'we' just have "concerns". Now some educated idiot thought this up so everyone would feel comfortable. Quite frankly I don't give a damn how comfortable anyone feels when there is a problem. It is just a damned problem that needs fixed, so 'we' need to get off our ass and fix it !!!! - Good Lord - (mumble, mumble) Photo #2 - I started the more complicated pieces today. Each was sawed, sanded, fitted, re-sanded then a dab of 5 min. epoxy here and there to attach them. Tried not to get any epoxy where I will be sanding. Will probably need to glue blocks to blocks until I can shape the top view properly. After I get all of this blocked in I will coat it with drywall compound and then do a final shaping and sanding. At that point will probably wrap the whole thing in plastic packing tape (wide Scotch Tape-(tm))prior to laying any fiberglass. The plan is to cut it off in 2 pieces. I want a top half and a bottom half. That is today's plan at least. Haven't quite decided on how I am going to cowl in the air filter. May make a separate piece for that. Photo #3 & 4 -Top front is close to shape now and these photo's show how I decided to fill in the bottom. Nothing except profile shaped at this point. I simply used one inch slabs of Dow(tm)Blue Foam that I picked up at the lumber yard. Held them in place with 6 penny nails while the 5 min. epoxy dried. Crap ..... I lofted the bottom of the center former WRONG ....... crap ........ now I must fill and redo part of it. Photo #5 - When I arrived home after watching Dennis Robinson put the second flight on T.L. Hillis' Murphy Renegade (fly's good) I found my Culver Prop had arrived. It is very well done. Hope it works as well as it looks. Cowl still rough but getting closer. May have it by this weekend. (dreamer) Bottom Row
Photo #2 -Cowl
is now ready to fiberglass. I have all of my fiberglass cut to shape and
laid out in the order each piece will be applied. Probably overkill but
I will have 2 layers of 12 oz. on one layer of 6 ounce cloth. (NOTE: Wasn't
overkill -need 2 more layers of glass - total of 5 layers)
Photo #4 -Put
on two layers of 12 oz. cloth today. The final 5 oz. layer didn't
want to wet out so pulled it and will go with what I have. If I need
another layer will put it on later. (NOTE--it did and I did) I will
do most of my sanding and filling while it is still on the plug and probably
won't pull it off for a week. Just to make sure I have a good epoxy
set. The bottom was a trip. Best way for me was to wait until
the epoxy started to set up .... 10-15 minutes and then apply it to the
bottom. It stayed put that way. Seams were overlapped and after
an hour or so I trimmed ugly edges with a razor blade and pulled the edges
off, making a nice line for sanding. I am happy with the lay-up but
did need two more layers of 12 oz. fiberglass for enough rigidity.
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