The bottom cowl fit is a bit of a nightmare. I’ve put more than two full days into it so far and just getting closer. The cowls as supplied and my plane don’t match. They are a bit too wide at the firewall and not even close anywhere else. My spar, wings, strakes and firewall are not exact to the millimeter in their respective levels. I doubt anyone’s ever are. If yours are, my congratulations tinged with mild amazement.

Meanwhile who cares about other peoples skills? I am adverse to the comparison game and the need to be better or even keep up with others. I’ve learned over time to not even allow those thoughts to linger. The job is to fit the bottom cowl.  I don’t need any negative mental chatter. Lets quietly get this done. That means ‘at it’ every day.

Here’s what we have to work with.

Ok, its also like herding cats blindfolded. <grin> Those old computer and phone books I’ve used through the build and are great spacers, easily adjustable. Those have to come out each time I move the cowl for a trim. Oh and you might not a bit of wood on the outside on the left on the fuselage to help fitting.

I’ve been on and off those books I guess 30 or 40 times in the last two days. That spinner has been great for getting the cowl centered and ensuring the opening is even upper and lower relative to the middle of the crankshaft.

This was an early big trim. From here I’ve just been taking .05 to .1″ off each time to get the sides closer. I’m very mindful that taking too much off is not going to work out well so I’m being very cautious.

As I keep removing material and resetting up the positioning I am getting a feel for how it wants to sit. You can’t just lop a bit off the sides per a measurement. As one thing moves so do others. The fit needs to be seen as a whole.

I’ve now trimmed the top cowl a little and later did some of the bottom. I have wooden blocks hot glued to the outside to help the fit. As I continue today I’ll be hoping to get to the point of hot gluing the cowl in place from on the outside so I can do the internal lip layups. Its nearly there.

I’m working hard to try and get a relaxed fit. Because one side is a bit proud of the firewall vertical line I’m going to have to force that bit in. After the internal glass lips and cure I may try a bit of heat when its clecoed in place. During all this I’m very mind full that these cowls are going to come off and on a lot. While it may not be pretty and a perfect flush fit initially, I’m trying my hardest to have a good result.