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Oil dipstick door installation on Lightning cowls

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Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Fri Jan 22, 2010 6:13 am Post subject: Oil dipstick door installation on Lightning cowls

I can't find any instructions one the owners list (inside with something else?) and don't think I have any hardware for the dipstick flap though I have found a bit of piano hinge that maybe Jab or Esqual or maybe even Lightning that came will my new cowls (LS for my Esqual).  

I have some Jabiru bits and will have a play with them. I didn't fit the Jab one on my SP as the cowling comes off so quick.   

The Esqual was the same but as the Lightning has some many screws I won't be taking the top off off at every pre-flight which I imagine is the standard approach.  

Can someone tell me what the Lightning installation is like?   

Thanks, Clive     [quote][b]

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sttwig

Joined: 26 Aug 2007
Posts: 31
Location: Yakima, WA

Posted: Fri Jan 22, 2010 10:51 am Post subject: Oil dipstick door installation on Lightning cowls

Clive,



I had the same question to Lightning headquarters in Tennessee.  They said they use some hinge and rivets to attach the door.  I didn't care for trying to hide the rivets on the exterior of the cowl so I bonded the hinge with Aeropoxy to both the door and the cowl.  It hasn't stood the test of engine and flight operations yet, but I don't see why it won't work.

 

Steve Sundquist

Kit #48



On Fri, Jan 22, 2010 at 6:09 AM, James, Clive R <clive.james(at)uk.bp.com (clive.james(at)uk.bp.com)> wrote:

[quote]           

I can't find any instructions one the owners list (inside with something else?) and don't think I have any hardware for the dipstick flap though I have found a bit of piano hinge that maybe Jab or Esqual or maybe even Lightning that came will my new cowls (LS for my Esqual).   

I have some Jabiru bits and will have a play with them. I didn't fit the Jab one on my SP as the cowling comes off so quick.   

The Esqual was the same but as the Lightning has some many screws I won't be taking the top off off at every pre-flight which I imagine is the standard approach.  

Can someone tell me what the Lightning installation is like?   

Thanks, Clive      	  Quote: 	
		  



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tp://forums.matronics.com

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[b]

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Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Sun Jan 24, 2010 3:43 am Post subject: Oil dipstick door installation on Lightning cowls

Thanks Steve, how did you get it flush? 



I've been playing around with some bent metal to set the hinge back and

move the pivot point away from the door. So door can site flat on the

rebate.



If I can't get there wit that I'll go your way, Cheers, Clive 



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sttwig

Joined: 26 Aug 2007
Posts: 31
Location: Yakima, WA

Posted: Sun Jan 24, 2010 9:35 pm Post subject: Oil dipstick door installation on Lightning cowls

Clive,



I hope these pictures help.  I cut the joggle completely away on the hinge

side and made a notch for the hinge to fit in.  Also, per Mark's suggestion,

I stiffened the door and the area opposite the hinge, between the camlocs

with some angle.  He said the cowl tends to warp there due to the heat of

the engine.  He sent me a picture, but it is on my work computer.



Steve



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selwyn

Joined: 12 Mar 2008
Posts: 102
Location: Australia

Posted: Sun Jan 24, 2010 9:37 pm Post subject: Re: Oil dipstick door installation on Lightning cowls

Hi guys,



I'm thinking about the same thing at the moment and a couple of problems are exercising my imagination.



First is the warping that happens to Jabiru oil doors and other thin glass covers, particularly when exposed to heat over time.  Second is, as you have noticed, the thickness of the door plus simple piano hinge is greater than the depth of the rebate in the cowl so the thing won't sit flat even before it warps.  Jabiru uses a hinge set on the inner surface of the cowl and curved piece of metal or glass (depending on the model) to attach to the door and provide clearance for it to open.  A similar principle to the Lightning canopy hinges.



I have yet to drill the holes but my current solution is to throw the hinge away and use four camlocs, one at each corner, to hold the door in place and help to keep it flush with the cowl.  Some sort of tether to stop the hatch blowing away when removed would complete the job.



Any thoughts?

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_________________
Cheers, Selwyn
Kit 66 VH-ELZ

Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Mon Jan 25, 2010 11:13 pm Post subject: Oil dipstick door installation on Lightning cowls

Thanks guys, all good info.



I recall the latest Jab's have an ally plate for the door, this must be

their solution to the warping.



I'm still not decided on the solution and the exclusive use of camlocks

was also on my list as it's quick and easy! (thanks Selwyn).



The door area on my cowl is already warped an although I could heat it

and flatten it I'm sure it would revert without a metal back up.



It was because of the hassle associated with such a small part that made

me glass the hole up on the previous two occasions.



Thanks again, Regards, Clive



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selwyn

Joined: 12 Mar 2008
Posts: 102
Location: Australia

Posted: Tue Jan 26, 2010 9:10 pm Post subject: Re: Oil dipstick door installation on Lightning cowls

Hi Clive, Steve,



Just so I don't lead anyone up the garden path I thought I'd confess that, after reading Steve's, post I'm part way through implementing a similar solution to his. (Thanks Steve).



My cowl has also warped around the oil door cutout, particularly along the outboard edge and, as you say, will probably get worse over time so the metal reinforcement seems the way to go.  That will probably print through over time but that seems the lesser of two evils.



I had a chat to my fibreglass guru and his advice is to drill holes through the hinge and cowl and bond it on with epoxy and floc so that an epoxy "rivet" is formed to help key the metal to the glass.  A layer of glass over the top as per Steve will complete the job.

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_________________
Cheers, Selwyn
Kit 66 VH-ELZ

rick(at)trickair.com
Guest

Posted: Wed Jan 27, 2010 5:41 am Post subject: Oil dipstick door installation on Lightning cowls

Hello,

I wouldn't drill through the cowl,  that will certainly print through. Do

drill through the hinge. I suggest that you clean and completely scuff the

area around the door opening add several layers of glass or strips of carbon

fiber around the opening. Then bond on the hinge and a metal reinforcement

if you want. The adhesive of my choice for boning metal to fiberglass is a

methacrylate. Some name brands are Plexus MA310 or MA300.  Another is

Weld-on. 



Regards

Rick Discher

Custom Fiberglass Molding 

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