Step 4: Lower Inlet Ring and layups

I mixed up a batch of epxoy/balloons and put the small inlet ring in place. I suspended the cowl up a bit off the floor so the ring wasn't resting on the floor. I poured in the mixture and let it cure. Put enough in to fill in the groove but not so much as to not leave enough ring to attach too.



I pinned the top and bottom cowl halves together and started doing layups where the top and bottom meet at the front. I used some clear masking tape on the top half to keep it from sticking. I also used some aluminum strips and cleco's to hold the top/bottom half together to keep it from shifting.





It was a challenge doing the layups way down inside!

Now trim those layups to give some nice smooth edges. With the cowl pinned together and clamped in position, drill two holes on each side to #8 CS screws. Install nutplates on back sides of new layups. Countsink the holes on the top cowl to accept a countersunk washer.