teamgrumman(at)yahoo.com
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 Posted: Mon Nov 25, 2013 11:29 am Post subject: Sweet 16 progress |
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Figure about 30 to 35 hours to get to this spot. Seems like forever. Quite frankly, after about 5 or 6 hours of tedious trimming, fitting, installing, removing, trimming, fitting, installing and removing I'm exhausted and I have to quit for the day or find something else to work on.
Once the basic fitting of the upper cowling is finished, 10 pilot holes for the cam-locks and 2 pilot holes for nut plates need to be drilled. Then, 38 pilot holes for the hinge need to be drilled. Then the upper is final trimmed, then riveted.
I'm having Composite Dave make a new master cowling with simpler exit ramps and better defined trim lines. Hopefully, this will decrease install time.
One of the most difficult parts of the entire installation process is fighting the urge to trim the fiberglass and not move the engine.
Case in point: N1540R.
I fitted my original cowling to a mockup by moving the engine around until the engine fit the cowling. Then I pre-fit Sweet 16 to the mockup with the engine set to my cowling. The trim lines on the fiberglass and the drew holes were pretty close; within a few millimeters.
When I got N1540R and started fitting the cowling to N1540R, it seemed WAY off. Adding one thick shim on the bottom right and one thin shim on the upper left fixed the alignment. I really wanted to just trim off an 1/8 inch on one side of the cowling. Moving the engine is a pain.
Aligning and fitting the upper cowling takes about 5 to 8 hours.
Gary
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