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How to install the cowling sink plates?

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john.marzulli(at)gmail.co
Guest

Posted: Fri Jan 01, 2010 10:23 pm Post subject: How to install the cowling sink plates?

There are some details lacking in the Zenith instructions for the new style FFW cowling install. 

  

 I have my cowling clecoed on, but am not sure about how to use the sink plates.

  

 Based on the instructions/HBH video, it seems like the process is this:

  

 1) Get the cowling positioned and clecoed together.

 2) Drill out the forward four holes where the split pieces join

     A) to AN5 on the top piece ( to let the washers rest "counter sunk" )

     B) to AN3 on the bottom piece

 3) Attach the nutplates to the bottom half.

  

 So based on this I have a few questions

  

 1) How do I keep the cowling lip as nicely aligned as I have it now? I would guess that since the holes are a little large that there is some slack.

 2) Since the recieving shaft of the nutplate is larger than AN3, I will assume that the plate gets riveted to the inside. What is the best procedure for drilling the holes for the rivets without loosing alignment?

  3) I am supposed to countersink the rivets for the nutplate. How do you countersink thin fiberglass like this? Making a dimple seems like a bad idea. Using a drilling reamer/countersink seems worse. The directions call for the holes to be enlarged to #30, but not which rivets to use. The soft brass A3s fit without enlarging, but the dome head would cause a poor fit...

   

  

  

 Many thanks in advance,

 John Marzulli



http://www.GenevieveMarzulli.org/

http://MarzulliPhoto.net/

http://701Builder.blogspot.com/

 

  [quote][b]

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john.marzulli(at)gmail.co
Guest

Posted: Mon Jan 04, 2010 6:12 pm Post subject: How to install the cowling sink plates?

Thanks,

 

I mistakenly called them "sink plates" when I meant "nutplates".

 

Zenith finally reopened from the holidays and I was able to get in contact with Roger. As always he was able to straighten me out.

   

 It turns out the manual is partially wrong compared to how Zenith shipped my cowling.

  

 Roger confirmed that you are indeed supposed to bore a counter sink hole into the fiberglass to hold the nutplates onto the inner lip of the bottom half of the cowl.

  

 Zenith is now suggesting leaving the holes on the plates at their current size and using A3 sized blind rivets.

 

Here are some photos I took on Sunday of the project: http://marzulliphoto.net/Airplanes/Spinner-and-Cowl-questions/10852940_KXmXA/1/757077715_7r2hC

  

 

Thanks again,

 John Marzulli



http://www.GenevieveMarzulli.org/

http://MarzulliPhoto.net/

http://701Builder.blogspot.com/

 

 On Fri, Jan 1, 2010 at 10:22 PM, John Marzulli <john.marzulli(at)gmail.com (john.marzulli(at)gmail.com)> wrote:

 [quote] There are some details lacking in the Zenith instructions for the new style FFW cowling install. 

  

 I have my cowling clecoed on, but am not sure about how to use the sink plates.

  

 Based on the instructions/HBH video, it seems like the process is this:

  

 1) Get the cowling positioned and clecoed together.

 2) Drill out the forward four holes where the split pieces join

     A) to AN5 on the top piece ( to let the washers rest "counter sunk" )

     B) to AN3 on the bottom piece

 3) Attach the nutplates to the bottom half.

  

 So based on this I have a few questions

  

 1) How do I keep the cowling lip as nicely aligned as I have it now? I would guess that since the holes are a little large that there is some slack.

 2) Since the recieving shaft of the nutplate is larger than AN3, I will assume that the plate gets riveted to the inside. What is the best procedure for drilling the holes for the rivets without loosing alignment?

  3) I am supposed to countersink the rivets for the nutplate. How do you countersink thin fiberglass like this? Making a dimple seems like a bad idea. Using a drilling reamer/countersink seems worse. The directions call for the holes to be enlarged to #30, but not which rivets to use. The soft brass A3s fit without enlarging, but the dome head would cause a poor fit...

   

  

  

 Many thanks in advance,

 John Marzulli



http://www.GenevieveMarzulli.org/

http://MarzulliPhoto.net/

 http://701Builder.blogspot.com/



[b]

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Mike Hoffman

Joined: 11 Mar 2006
Posts: 54

Posted: Tue Jan 05, 2010 3:45 am Post subject: Re: How to install the cowling sink plates?

Hi John, Nice looking project. What are the landing lights you used and where did you get them?

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john.marzulli(at)gmail.co
Guest

Posted: Tue Jan 05, 2010 7:49 am Post subject: How to install the cowling sink plates?

They are automotive lights meant for rally racing or offroading. I was given them years ago to put on my Jeep.

  

 I no longer have the box, so no model number. The brand is IPF.

  

 thanks,

 John Marzulli



http://www.GenevieveMarzulli.org/

http://MarzulliPhoto.net/

http://701Builder.blogspot.com/

 

 On Tue, Jan 5, 2010 at 3:45 AM, Mike Hoffman <mhoffman9(at)tampabay.rr.com (mhoffman9(at)tampabay.rr.com)> wrote:

 [quote]--> Zenith701801-List message posted by: "Mike Hoffman" <mhoffman9(at)tampabay.rr.com (mhoffman9(at)tampabay.rr.com)>

 

Hi John, Nice looking project. What are the landing lights you used and where did you get them?





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