Trimmed aft edges of both Top and Bottom Cowls per Steps 11 & 12 at 45-05. Cleaned up mating surfaces per 45-06 Steps 1-4. Started 45-07, aligning Top to Bottom along mating surfaces, holding with clamps. After couple iterations, getting close.... Received new Cowl Pin Covers from Aerosport Products. Will replace external tabs & screw in Vans design with these flush mount beauties ! Also received from Aircraft Spruce the large AN526A(soft)6-7 rivets. These 3/16" dia rivets will fill the 1/4" holes pre punched in Oil Door for Quarter Turn fasteners - also external. I'm using the KM610-64 latch that mounts flush (used on Cessnas, and many other RV builders). Pricey, but like the flush, easy open design. I bought mine at Aircraft Spruce (others were lower cost, but charged much more for shipping). So I practised filling a couple 1/4" holes in same thickness alum today. C'sink almost flush topside, then slightly C'sink bottom to insure rivet retention.
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| Until I got to this point, was concerned about how the top and bottom would be aligned. But Vans has good instructions and procedure. |
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| Looking good! Cowl Pin Covers with Left and Right templates |
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| Revising Oil Door to fill two 1/4" holes in corners. Plan to mount Cessna style KM610-64 latch instead. |
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| Trial filling of 1/4" holes with large "soft" 3/16" dia rivets. Will be able to get smooth top surface |
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| 3/16" rivets easily expands to fill 1/4" holes. Shallow C'sink on bottom, so not sure if grind smooth, or leave some for strength. |