I originally wasn't going to work on the project today, but I felt like crap when I woke up and didn't feel like going out. I made up the hinge and 020 spacer for the bottom cowl to attach to the side of the fuselage.
I put a block of wood under the bottom of the hinge to keep it from folding back when I drilled it to the side of the cowl.
After trimming the side (many iterations of course), I drilled two holes to hold the side on.
With the sides on, the only thing left to do is attach the top to the bottom. First, the top needed to be trimmed to the contour of the bottom cowl. I drew a line on the top cowl using the bottom cowl's top edge as a guide.
This was the best trim yet. I only needed to sand a little bit more than I did originally, and there was NO GAP on the side. Really a work of art.
Here's a closer shot. PERFECT.
Next I drilled some 257-P5 hinge to the side, offset upward by 1/4" as dictated by the James instructions.
The P5 hinge is SUPER wide stuff.
I am trying to install my hinge pins from the inside so I don't need any unsightly access panels on the front of the cowl. I drilled a #40 hole in the firewall for the pin to go through.
Here is a shot from the inside to show where it comes into the fuselage. I still have no idea how I am going to secure it, but I can figure that one out later.
I think I will have no problem getting the pin to feed into the cowl halves by myself. I put the eyelet on the bottom cowl closest to the firewall so I can feed the pin into it to get it started. Once I put the top cowl on, I can get in the fuse and push the pin in.
I made up the top half of the hinge pin and drilled it with some holes. My thought is I will be able to see the holes through the fiberglass and just drill freehanded.
DONE! Well, not really, but pretty close. So far the cowl has been the hardest part of the project. I don't know if it is because it is the James cowl or what. Who cares! I really fought with this thing over the past month(s), probably taking it off 100's of times.
Last Modified: June 5, 2023