Does anyone know if the older metal cowl extensions will fit newer cowls my kit is #4633, if they will work any idea where they could be found.
Chris RV 4 N1212R
I fabricated custom ones for an RV-3 repair job. A slip roller machine would have helped, but I was able to do it with hand tools. It did take two tries and quite a few shims to get the forward bulkhead to look good and match the cowl.
Too bad people that can use a English Wheel is becoming a lost art, wish I could do it. There was a video of a really old guy making a radial engine speed ring out of flat stock, it was amazing.
I'm a true metal guy, and I can use an English wheel, also built my RV4. Metal extensions while are quite nice may be a tougher fit than the glass ones which are pretty robust. I had similar thoughts, but very pleased with the rigidity and fit of the fiberglass ones .
I fabricated custom ones for an RV-3 repair job. A slip roller machine would have helped, but I was able to do it with hand tools. It did take two tries and quite a few shims to get the forward bulkhead to look good and match the cowl.
I should add that I now recall that getting them down to a point is pretty impossible in metal. So what I did was trimmed the end off at about 1" and made a 3D printed tip to finish off the point.
I did the work with .032" 2024-T3, and that was a bear. It was in the middle of a bunch of shortages and thinner stock wasn't available.
Anyone have any photos of the cheek extensions where they end at the cowl? I have seen one other and it looked great!
Mine seem to have a gap at the top. With a wood prop, I won't be flying in the rain, but it does look like a great rain catcher! I was thinking about glassing it in or making a cover plate of some sort. Any suggestions? That is not the best photo of it but I am sure you get the jest. It just looks crappy....
Sand a foam core to match the cowl. Three layers of glass are perfect because it is a curved cone. Put flanges turned inside, not out for classy appearance. Glue / poprivet fuse to flange sparingly.
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