Home > Canopy Release, Cowling, Instrument Panel > Mostly More Cowling – 10 hrs

Mostly More Cowling – 10 hrs

Sunday July 14, 2013

Most of my time this weekend was spent working on the cowling but I also did a few other things just to keep things interesting. First I made labels for my annunciator panel lights. All I did was print out the labels on plain paper on my laser printer and cut them out to fit in the lights. When you pull the colored lens off each lamp there is a diffuser underneath. I put the label between the diffuser and the lens.


I also made a handle for the canopy release mechanism. The stock handle is long enough to extend out through the instrument panel. I cut it down so it just protrudes past the subpanel when the mechanism is in the latched state. I slotted the tube and drilled a hole for the link pin.


Here is the handle installed on the mechanism in the latched state. I will install the cotter pin later because I know I still need to remove the subpanel to cut a hole for the radio stack.


This view is from the aft side. That adel clamp is not installed yet but I marked the location for a hole and I will install a nutplate there when I pull out the subpanel.


I also started installing the VHF com antenna. Mine is a Comant CI-122 and I am installing it below the pilot’s seat in the most outboard bay. I made a doubler out of some .032 stock alclad including two angles to stiffen it up side to side.


I located it aft of the main spar and as far forward as I could to keep it as far from the ADSB antenna as I could. That put it right under the aileron control rod. I will probably have to install a 90 degree coax connector on the cable for the antenna to keep the cable away from the control rod. I still need to rivet the doubler in place.


But most of my time was spent on the cowling. I picked up some high-build primer at ACS on Saturday and sprayed the top cowling section. Boy it is nice to see the pepto pink disappear. I put on three light coats of primer. After it dried I sanded it out with 400 and 600 grit paper and it is nice and smooth. The oil door was sprayed separately.


The lower cowling still needs a lot of work on the exterior. It is covered with thousands of pits due to the honeycomb layup. So I started filling the pits with slightly thinned epoxy. I started with one coat squeegeed on with a single edge razor blade on the surfaces that are more or less horizontal in this view. It does no good to apply it to the vertical surfaces because it just runs out of the pits. When the first coat was cured about an hour or so and was stiff and sticky I brushed on a second heavier coat – hopefully enough to completely fill the pits. Now I will let it cure so I can sand it out to see if another coat is required.


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