@#$%) Cowling

[dsm8]

Good Afternoon:

. My first attempt started prior to engine arrival and installation and took the advice of many on the forum to wait until the engine arrived. Upon engine installation the trimming I completed during the first attempt was too aggressive, leaving unsightly gaps on the side, left worse than the right. Attempts to add some fiberglass to close the gap and retrim were met with not very good results. I ordered a new bottom cowling and followed the directions exactly. Now it appears the whole assembly is off center by about 1/4 to 1/2 inch. to adjust it I un-clecoed the top cowling rotating the left side aft without much improvement. Every other fitting is spot on and I am pleased with the way it cam out. My question is:

1. Live with it, which I can do because it was never going to be a show plane and after 10 years of building I want to fly it.
2. Order a new top cowling and start over. The new bottom cowling was nearly ten aviation monetary units ($1,000) including shipping.

Any advice would be greatly appreciated

 

[CTCole]

Got to be frustrating, but the cowling edge can be rebuilt. When completed the repair is as strong & invisible as the original. I cut one of the upper sides too much, had to build back about 1/8". The trick was to include fiberglass cloth on the inside, and clamp a flat form (with wax paper) on the outer, finish side, then trim back to the desired dimension. Some photos attached.

 

[thehagg501]

Good Afternoon:

. My first attempt started prior to engine arrival and installation and took the advice of many on the forum to wait until the engine arrived. Upon engine installation the trimming I completed during the first attempt was too aggressive, leaving unsightly gaps on the side, left worse than the right. Attempts to add some fiberglass to close the gap and retrim were met with not very good results. I ordered a new bottom cowling and followed the directions exactly. Now it appears the whole assembly is off center by about 1/4 to 1/2 inch. to adjust it I un-clecoed the top cowling rotating the left side aft without much improvement. Every other fitting is spot on and I am pleased with the way it cam out. My question is:

1. Live with it, which I can do because it was never going to be a show plane and after 10 years of building I want to fly it.
2. Order a new top cowling and start over. The new bottom cowling was nearly ten aviation monetary units ($1,000) including shipping.

Any advice would be greatly appreciated

Wait a minute..... I thought an amu = a grand?

 

[wirejock]

Got to be frustrating, but the cowling edge can be rebuilt. When completed the repair is as strong & invisible as the original. I cut one of the upper sides too much, had to build back about 1/8". The trick was to include fiberglass cloth on the inside, and clamp a flat form (with wax paper) on the outer, finish side, then trim back to the desired dimension. Some photos attached.

I agree. Easy fix if you are so inclined.
I'm a fan of molds. I find stuff that works or modify. Thrift stores, dollar stores, etc. Find something the same shape or make a mold from the existing before working it.
As mentioned, build up the inside first. Sand off the part you don't want. Apply a bunch of flox with a layer of fabric over. Wax the mold then use it to form the nose the way you want it. Cure.

The other cowl is repairable too. I trimmed too much. I sanded a scarf the length of the side and added a few layers with a piece of aluminum clamped as a mold to hold shape. After curing, I added layers till it was the correct thickness.

 

[ge9a]

As stated above, fiberglass can ALWAYS be fixed/repaired/modified. I know because I've messed up a lot of parts and fixed them, similarly to what has been described above. Patience is the key, and there will always be sanding and more sanding. At least for me.

Bottom line, I agree with the above suggestions and fiberglass parts can always be salvaged.

It's a learning process.