11.1 Engine Cowl Mod

This entry is part 4 of 17 in the series 11 - Fairings

You may remember all the work that has been done to get the engine to fit: two of the intake tubes were replaced with custom built tubes to clear the cowling and then a hole was cut in the cowling for the main air intake.

Now it’s time to, sadly, modify the cowling so the air intake will fit.

Here’s a side, top and inside view:

 

I drew a shape to provide a symmetrical guide and rounded it out.  Then I made the cut and sanded the surrounding area.

To prevent an “bubble” where the hole was, I made relief cuts around the opening. Then I cut a piece of foam that was a little smaller than the relief cuts to go under the cowling. I large piece of aluminum sheet went under that. Then I made a “plug” out of triax that I covered with duct tape.

Then the area was covered with two progressively larger layers of BID.

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