On a follow up thought, with reference to the Vans instructions for constructing the cowling, the cowling installation remains the (at least one of the) most challenging aspect of the entire project. As a mundane step in the building process, it also has the ability to define the entire quality of the finished product. For years, I (Skybolt) have received our fair share of criticism for lame instructions reference the cowling. The most criticism has been the lack of diagrams or drawings. Basically, our instructions have simply said ?install parts? assuming the builder has vast experience with ?-Turn Fasteners. Possibly, a bad assumption. I then turned to the Vans instructions to see if I might pick up some guidance from a better perspective. My opinion was that the Vans Air Force Forum had more tips and information on cowlings than both my instructions and Vans instructions combined. What was really missing was the best starting point. Here I have two cowling halves worth about $900 that are not even close to fitting. Why? The kits supplied by Vans in today?s world are CNC prepared so why can?t the cowling as well be better prepped for a final fit? In my mockup, I ordered actual Vans firewall and skins and found that the components fit perfectly. In defense of the cowling producers, they are attempting to cover multiple engine configurations, thus the cowling halves leave plenty of skin area for trimming. But trim where what and when? In other words, what sequence and where do I start? So I proceeded to write our new instructions based on my experience building both production cowlings and kit plane cowlings. As I worked my way through the process, I also made changes to the fasteners as well as fabricating inserts to ?clamp? the cowling after trimming the firewall without committing myself to the final hole locations. All the while, I assumed that the sequence I was using would apply to a hinge installation versus our CLoc ?-Turn fastener installation. In conclusion, I invited feedback from various builders and made appropriate changes. Skybolt has been shipping the newest version of our kits with the interlocking, precut flanges, and we are beginning to receive positive feedback. Knowing the vast amount of experience in the Vans world of outstanding aircraft, I continue to rely on tips and feedback on experiences so that Skybolt can write the best possible procedural instructions to make a mundane step in the overall build just a little bit more ?exciting?. At the end of the day, the cowling is one of the first things to define the finished product. It certainly gives us pride to walk the flight line and see the incredible craftsmanship, especially when our fasteners are used and showcased. We have made a vast improvement in our product and remain committed to advance as the Vans product advances. Your feedback and comments help us provide the best design possible. Whether you plan to use hinge, CLoc fasteners, or a combination, I invite you to use our instructions as a guideline for installing and trimming the cowling for the best possible results. Please note our web address for instructions:
http://skybolt.com/Vans RV Cowling Installation 2011 Rev 4.pdf
To all our customers, my sincere thanks,
Ned Bowers