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09-11-2015, 07:24 AM
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Join Date: Aug 2011
Location: Jeffersonville, IN
Posts: 391
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Metal Cowl/Fairings
If you had the skill, tools, knowledge to make a any or all of the fiberglass parts from aluminum would you prefer metal? Maybe on some but not others? Why/why not.
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Jeff Scott
RV9A First Flight 9/30/19
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09-11-2015, 07:39 AM
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Join Date: Jan 2006
Location: Winston-Salem, N.C.
Posts: 1,210
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Pros/Cons
I am a aircraft metal worker by trade, and I do have the means to fabricate all the FG parts from metal, but..there are drawbacks. There was an RV-6 I believe in which this was done, and its a piece of art for sure. Its hard to beat the look a of a beautiful compound curved formed (usually polished) metal cowl and wheelpants. The downside is that the fabrication is slow and very tedious, and the finished product is so much more subject to damage, cracks, wear and tear. These FG parts on the RV's will withstand some serious abuse, and can be repaired/re-finished in short order. I will be fabricating a new metal cowling for my 1941 Aeronca Defender, but only out of necessity, as I want it original.
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Bill E.
RV-4/N76WE
8A7 / Advance NC
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09-11-2015, 08:48 AM
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Join Date: Oct 2014
Location: Metamora, Michigan
Posts: 209
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Having a metal polished cowl on my Cessna 140 I agree they look nice but are more susceptible to damage. My thought has been to replace a metal cowl with a CF or Kevlar cowl. Has anyone done this on an RV rather than FG?
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John von Linsowe
Michigan
RV-7
Cessna 140
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09-11-2015, 10:02 AM
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Join Date: Feb 2006
Location: Anywhere, USA
Posts: 1,132
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It has been done.
Did this 7A and an 8.
Bottom cowl easy.
Top cowl PITA
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Bruce (BOOMER) Pauley
Kathy (KAT) Pauley
RV 7A--"MISS MARIE"--- N177WD (SOLD FLYING)72742
VAF #582-----------------EAA LIFETIME MEMBER
EX -KC-135A -------------BOOM OPERATOR #3633
VAN'S FLIGHT------------#6930
See you in OSHKOSH
http://www.mykitlog.com/users/index....ley&project=84
=VAF= 2006-2020 DUES PAID 
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09-11-2015, 02:20 PM
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Join Date: Jan 2005
Location: 57AZ - NW Tucson area
Posts: 10,011
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The one easy exception is an all metal faring around the base of the windshield.
Easy to make with a home made large edge forming tool.
Shown in an old RVator article -
https://picasaweb.google.com/1054628...OrUkIa2g-KjJA#
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Gil Alexander
EAA Technical Counselor, Airframe Mechanic
Half completed RV-10 QB purchased
RV-6A N61GX - finally flying
Grumman Tiger N12GA - flying
La Cholla Airpark (57AZ) Tucson AZ
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09-11-2015, 03:29 PM
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Join Date: Aug 2011
Location: Jeffersonville, IN
Posts: 391
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I have the tools, and skill/stubbornness to do it if I wanted. Was curious though if people had any input on advantages/disadvantages of metal vs composite.
Obviously in the beautiful picture posted, the polished look required one to complete.
Reading about VOR antenna's I could see metal wing caps would NOT be a good idea for reception reasons.
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Jeff Scott
RV9A First Flight 9/30/19
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09-11-2015, 06:31 PM
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Join Date: Jan 2015
Location: KC, MO
Posts: 374
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If someone were stamping them out, I'd probably buy one. By hand, no thanks.
X
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RV-4 - 0-320 (160HP)
www.KCFlight.org
Tinker
ATP/CFI/II/MEI
N617TN
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09-12-2015, 06:10 AM
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Join Date: Nov 2005
Location: Asheville, NC
Posts: 2,690
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Quote:
Originally Posted by az_gila
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Mel is right. This piece is simple in comparison to cowl/tips but it still takes some skill. It took me two work sessions to make mine so it may have been faster that fiberglass. A number of us have done it.
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Bill Pendergrass
ME/AE '82
RV-7A: Flying since April 15, 2012. 850 hrs
YIO-360-M1B, mags, CS, GRT EX and WS H1s & A/P, Navworx
Unpainted, polished....kinda'... Eyeballin' vinyl really hard.
Yeah. The boss got a Silhouette Cameo 4 Xmas 2019.
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09-12-2015, 06:22 AM
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Join Date: Dec 2009
Location: Montreal
Posts: 1,456
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Scott Black
Old school simple VFR RV 4, O-320, wood prop, MGL iEfis Lite
VAF dues 2020
Instagram @sblack2154
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09-12-2015, 11:20 AM
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Join Date: Jan 2005
Location: 57AZ - NW Tucson area
Posts: 10,011
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Quote:
Originally Posted by rzbill
Mel is right. This piece is simple in comparison to cowl/tips but it still takes some skill. It took me two work sessions to make mine so it may have been faster that fiberglass. A number of us have done it.
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Don't know where "Mel" comes into it. 
But I made my windscreen fairing in two sections. The first one took an afternoon, the second one took an hour.
Making a glass one would have had many more steps and much more final smoothing.
The RVator instructions were easy to follow and just needed some careful cardboard template cutting and angle measurement.
The resulting part has more of a sharp corner than the pictures in the previous post, which probably was formed with a shrinker or by hammering.
__________________
Gil Alexander
EAA Technical Counselor, Airframe Mechanic
Half completed RV-10 QB purchased
RV-6A N61GX - finally flying
Grumman Tiger N12GA - flying
La Cholla Airpark (57AZ) Tucson AZ
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