Lower Cowling Flanges

The lower cowling flanges are made in much the same way as the upper, except it is much harder because gravity is working against you, so after wetting the wing, cowling, and glass, I let it all get tacky. Then I tried to fold and apply it too early, got really aggravated, and just brute-forced […]

Rigging of the Roll System

The first step of this section is to drill holes in the gear bulkhead and firewall and route the aileron push-pull cables through to the wing roots. This is easier said than done, and I spent the better part of an evening getting these fairly ridgid cables to pass through. Argh. Now that the engine […]

Upper Cowl-to-Wing Flanges

Here we’ve duct taped the upper cowling and sanded the wing surfaces down to the glass where the cowling meets it in preparation for the cowling flanges. This is a 5 BID layup that I wetted wing and the upper cowling, then wetted the glass out on plastic and folded in half and laid on […]

Rudder Cable Installation

Here we’re rigging the rudder system. First we’ve installed an AN111 bushing at each rudder and swage the timble onto the cable and attach it to the rudder belcrank with an AN3 bolt. Next we deflect the rudders out 4″ from the wingtip to determine the amount of cable needed at the wingroot to get […]

Cowl Joint Flanges

Here we’ve glassed the cowling together at the previous cut line, and glassed where we (accidentally) made the wing holes too big. It’s really almost impossible not to make the whole too big without the template, since the cowling will not go inside of the wings to allow you to mark it. So, you end […]

Cowl Relief Hole for Wings

There is a template for cutting your cowling wing openings. I elected (foolishly) not to use this, since I knew from previous fittings that I wanted to move the cowling prop opening slightly to get a more even spacing around my spinner. DO NOT DO THIS, it is much harder this way, and caused me […]