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Re: (22) Cowl ( Mike )

PostPosted: Tue Feb 22, 2011 8:17 pm
by planecrazzzy
Hey Guys,
Before I figure out the bottom piece of the Cowl....

I need to figure out my "Intake"...

Here's something I could make... I'll figure out the details later...

I made the base plate out of .125 aluminum...

and I had a piece of .025 for the box area...

I'll cap it with something later...
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Tue Feb 22, 2011 8:22 pm
by planecrazzzy
Hey Guys,

Here's the intake box "in place"

and a lower cowl pattern I was trying... the pattern didn't really work...

BUT.... it did get me close...
Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Tue Feb 22, 2011 8:30 pm
by planecrazzzy
Hey Guys,
Ok, The pattern didn't work.... But it got me "close"

From here... I cut the aluminum a little "Bigger" than the pattern...

and I used the lay out to cut the hole for the "Intake box"
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Next... Baby steps....

I put a few Cleco's where I could...

From here... I'll make some marks to form the plate and the existing cowling...
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Tue Feb 22, 2011 8:48 pm
by planecrazzzy
Hey Guys,
After some staring .... and some more staring...

I got an idea... I'd curve the panel toward the fuselage... and turn the existing cowling towards the panel...

I couldn't do this without the English Wheel... ( 8 inch Rubber wheel on top )

I need to have clearance for the exhaust pipes...

I think this design is better than my pattern , which had holes for the exhaust...

It took a little time to get the pieces to blend together...

But I like how it turned out...
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Actually , it is pretty simple.... Which I like.
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Tue Feb 22, 2011 9:02 pm
by planecrazzzy
Hey Guys,
A long thread... But , there's quite a bit to this...

The pieces have a good fit to each other...

Then , excess material was trimmed off...

One last check for clearance
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The exhaust has room to move without touching the cowl.
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Next... I'll be making the intake Scoop...
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Gotta Fly...
Mike & "Jaz" in MN
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Re: (22) Cowl ( Mike )

PostPosted: Wed Feb 23, 2011 9:02 pm
by planecrazzzy
Hey Guys,
I got the lower panel "prepped" and riveted today...

I used Stainless Steel Flush rivets where the cleco's were...

and soft hammered rivets were used in a "W" pattern for the overlapping pieces...
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Thu Feb 24, 2011 9:42 pm
by planecrazzzy
Hey Guys,
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I'm working on the lower intake scoop...

I gathered a little info... it'll help when I design this...

My first attempt failed... It was too small , and some angles were "OFF"
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I think the front was angled back too far...

I made the next one bigger and longer...

I moved it forward 2 inches
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Thu Feb 24, 2011 10:03 pm
by planecrazzzy
Hey Guys,
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This looks about right...

The paper is a "Ruff" idea...

The scoop will have rounded edges down it's length...

This should "Blend" with the style of the cowl...

I'll use the English Wheel... Then bend the angle 90 degrees...

it should end up a tight radius...
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The front of the scoop looks like a good angle to ram air...
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Thu Feb 24, 2011 10:06 pm
by planecrazzzy
Hey Guys,
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Here's a picture that helped me with the intake scoop...
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Gotta Fly...

Re: (22) Cowl ( Mike )

PostPosted: Sat Feb 26, 2011 9:24 pm
by planecrazzzy
Hey Guys,
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After a couple paper "mock ups"... I decided on this size...

The first one was too small , and the front angle was "layed back" too far...
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Gotta Fly...
Mike & "Jaz" the Flying Dog
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Re: (22) Cowl ( Mike )

PostPosted: Tue Mar 01, 2011 7:30 pm
by planecrazzzy
Hey Guys,
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On the Tailwind site , Jim C recommends Windshield adhesive for added strength on the riveted doors...

I was asking about my cowl... Somebody mentioned it... Sounded good...

I've seen how good that stuff sticks....

I found some at a couple auto stores.... it's by 3M

Mine was $18 bucks.... not cheap...

It fits in a caulking gun , and spreads like silicone...

It cleans up with Lacquer thinner.
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I got a little excess that oosed out...

I'll wait til it's dry before I clean it off...

Looks like a good seal....

The rivets should have a chance to help without vibrating a bigger hole now....
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Gotta Fly...
Mike & "Jaz" the Flying Dog
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Re: (22) Cowl ( Mike )

PostPosted: Thu Mar 24, 2011 10:24 am
by planecrazzzy
Hey Guys,
I made a front plate for the Air Scoop.

This will hold the air filter behind it.... and a 3M scuff pad in front

I'll be putting a "By-Pass" in it also...It'll work by ram air pressure
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The scoop has inserts put in it to hold the plate...

http://www.aircraftspruce.com/catalog/h ... tserts.php
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Thu Mar 24, 2011 10:41 am
by planecrazzzy
Hey Guys,
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OK, I found that my spare air compressor filters look like a good size to use...
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Gotta Fly...
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Re: (22) Cowl ( Mike )

PostPosted: Thu Mar 24, 2011 10:49 am
by planecrazzzy
Hey Guys,
Here's a look at my "Free Air" area...

The front of the scoop is "inset".... I figure it will "hold" air pressure...

as the pressure increases... the springs should let air "in".... by-passing the filter...
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This can be adjusted by spring pressure...

They only need to hold it closed at slow RPM ( For taxi )

Gotta Fly...
Mike & "Jaz" in MN
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Re: (22) Cowl ( Mike )

PostPosted: Thu Mar 24, 2011 10:56 am
by planecrazzzy
Hey Guys,
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For an outer screen , to catch the big stuff...

I think a 3M scuff pad will work great... it breathes very good...

I'll paint it white or silver later...

I still need to make an outer frame to hold the scuff pad and

clean up the "look" of the scoop entrance....
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Gotta Fly...
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