October 18, 2010

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This is a picture of filler (resin and milled fiberglass fibers) being added aroung one of the intake rings at the front of the cowl.   There just isn't any way to get a perfect fit without building it up with something that is strong enough hold and take a little punishment.

cowl intake

 

 

Here is the semi-finished product.  The fit is already pretty good. It needs just a little more shaping and sanding.

 

 

I used a similar technique to glue in the rings on the inside of the cowl.  I sanded everything with some 36 grit sandpaper first, made a dam from tape and poured in the resin and fiberglass fibers.  It seems to be adequately strong.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This is the final (I hope) louver design.  I am cutting them to an arbatrary size that will fit nicely under the cowl.

louvers

The next step will be to cut out the area for the louvers and install nutplates.

rv-7 louvers

Now for a little work on the wheelpants.  I measured the difference in thickness (actually just the matchup) between the front and back half of the wheelpants with the dial indicator.  That may sound a little too precision for the job, but it is an easy way to do it.  Now I will know how much to fill and grind to get them to match before I start match sanding.

 

 

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