When I was extending the cowling, I tried REALLY hard to preserve the joggle for the oil door - and failed. Some resin and filler got into the joggle, and I have been dreading trying to fix it.
As is usual, I have been pondering how to fix this for awhile and finally settled on my dremel with a round bit - kind of like an engraving bit (not sure exactly what its called). Then a flapper sanding drum.
The door is slightly too big and will need to be trimmed down slightly.
I think the plan will be to get it to fit as best as possible, and then tape up the door - put some filler in the joggle and cleco it in place, then pop it out and clean it up. I think that is the best option.
After a lot of sanding and grinding I have it fitting quite well. The cowl has been cut including the slot for the hinge. Still need to cut the slot for the latch and drill the hinges. Going to do the hinge first and cleco it in.
Hinge cut and drilled.
Its not bad considering the mess I made. But definitely needs cleanup.
So what I ended up doing...
- Put a single cleco on the aft end of the door to keep it closed - essentially where the latch is going to be.
- Put packing tape all along the oil cooler door
- Packed filler into the joggle
- Closed and clecoed the door
- Packed filler into the seam
- Let it dry, popped the door out
Well that worked about 70%. Needs some additional refinement. Below pic is of the 2nd fill.
So after all the high build primer the door doesnt want to fit anymore. Not a huge deal, but needs some love.
Done!
