Matt's RV-8 Project



Matt Dralle's RV-8 Project
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Date:  9-5-2009
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Fitting The Upper Cowling - Part 1

The seam between the cowling and the metal part of the airplane is called a "butt-joint" which means that the two pieces are cut perfectly flush to one another and meet up exactly. This is opposed to a "lap-joint" where one would overlay over the other. The problem with a butt-joint is that its incredibly difficult to get the two pieces to align very well if you cannot sheer them together. The RV cowling is about 1.5" longer in the back than required so this means that when initially fitting the cowling it will overhang the metal fuselage by the same amount. Before the cowling is placed on the fuselage, you take a ruler and carefully mark back from the metal joint exactly 2" all the way around where the cowling will form a butt-joint with the fuselage. The cowling is then placed on the fuselage in exactly the final installation position making sure that there is about 3/8" clearance back from the spinner. Then, using the 2" setback marks, the same line is drawn on the top of the cowling, transferring an exact butt-joint line between the cowling and the fuselage. In practice, it works amazing well. There's still a bit of fitting/filling/fitting/filling required, but the fit came out amazingly well.

Once the cowling was cut and filed exactly, the hinge holes are marked and then drilled.
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Fuselage Marked 2

Fuselage Marked 2" Back From Line Then Cowling Cut

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Fuselage Marked 2

Fuselage Marked 2" Back From Line Then Cowling Cut

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Upper Cowling Drilled

Upper Cowling Drilled

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