Rebel - Four Door Metal Cowling

rognal · Post by **rognal** » Sat Feb 18, 2012 9:05 am

All,

I'd like to build the metal 4 door cowling as shown on Wayne's website and in
the photo archives. I've checked the mail archives but no where have I seen
described the materials to be used. Can someone advise me what type/thickness
aluminum sheet is used to fabricate the door panels? Also, what
type/thickness aluminum sheet for the firewall to nosebowl longerons that the
door panels hinge on? Any construction hints or tips?

Thanks for any help,

Roger Hoffman #687R
Eugene, OR USA!

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Wayne G. O'Shea · Post by **Wayne G. O'Shea** » Sat Feb 18, 2012 9:05 am

.032 or .040 lip formed and riveted around the rear edge of the glass nose
bowl for the doors to sit flush on and for "longerons" to mount to.

I then made the side and top "longerons" by using 3/4" x 3/4" x .025 (or
.032 - can't remember) angle and then the hinge on top of that with a .025
sheet overtop joining the two hinge/angle combos. This way the angle can go
behind the bowl lip and firewall lip and the sheet goes on the outside.
Anchor nuts on angle piece inside allow screws to sandwich the lip between
them. Doors are/where .025 I believe... as .020 is a bit flimsy for this.

When it comes to the air intake area you need to place your angle to each
side of it with hinges for the bottom doors and then fill in between them to
fit in front and behind the air filter as you see fit.

Unfortunately all my pictures for detail while building where taken on the
old Canon and I don't have a scanner that works anymore in the house.

Wayne

----- Original Message -----
From: <rognal@dcsol.com>
To: <murphy-rebel@dcsol.com>
Sent: Sunday, March 07, 2004 10:04 PM
Subject: Rebel - Four Door Metal Cowling

All,

I'd like to build the metal 4 door cowling as shown on Wayne's website and

in

the photo archives. I've checked the mail archives but no where have I

seen

described the materials to be used. Can someone advise me what

type/thickness

aluminum sheet is used to fabricate the door panels? Also, what
type/thickness aluminum sheet for the firewall to nosebowl longerons that

the

door panels hinge on? Any construction hints or tips?

Thanks for any help,

Roger Hoffman #687R
Eugene, OR USA!

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Wayne G. O'Shea · Post by **Wayne G. O'Shea** » Sat Feb 18, 2012 9:05 am

Yah, you're right Ken! Probably just .020 for the doors and indeed .032 for
the angles...my memories fading from breathing all this alum dust!!

As for the piano hinges once I had mine all set up and painted I could no
longer use the .090 (or something close to that) hinge pins that come with
the hinges. Swapped out for stainless .063 that is nice and easy to
install.......yet not too sloppy to cause any wear problems. Readily
available from your local welding supply house as TIG filler rod in 1/16"
stainless.

Wayne

----- Original Message -----
From: <klehman@albedo.net>
To: <murphy-rebel@dcsol.com>
Sent: Sunday, March 07, 2004 10:51 PM
Subject: Re: Rebel - Four Door Metal Cowling

Further to Wayne's comments, the MAM cowl kit with two top doors uses
0.032 for the longerons and 0.020 for the doors and all the cowl skin.
At least it did 10 years ago for 119R...

FWIW I went to a lot of trouble to put latches on the top doors. If I
did it again I'd just use the piano hinges as per the manual as they
seem to work better than I expected.

good luck
Ken

rognal@dcsol.com wrote:
All,

I'd like to build the metal 4 door cowling as shown on Wayne's website

and in

the photo archives. I've checked the mail archives but no where have I

seen

described the materials to be used. Can someone advise me what

type/thickness

aluminum sheet is used to fabricate the door panels? Also, what
type/thickness aluminum sheet for the firewall to nosebowl longerons

that the

door panels hinge on? Any construction hints or tips?

Thanks for any help,

Roger Hoffman #687R
Eugene, OR USA!

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klehman · Post by **klehman** » Sat Feb 18, 2012 9:05 am

Further to Wayne's comments, the MAM cowl kit with two top doors uses
0.032 for the longerons and 0.020 for the doors and all the cowl skin.
At least it did 10 years ago for 119R...

FWIW I went to a lot of trouble to put latches on the top doors. If I
did it again I'd just use the piano hinges as per the manual as they
seem to work better than I expected.

good luck
Ken

rognal@dcsol.com wrote:

All,

I'd like to build the metal 4 door cowling as shown on Wayne's website and in
the photo archives. I've checked the mail archives but no where have I seen
described the materials to be used. Can someone advise me what type/thickness
aluminum sheet is used to fabricate the door panels? Also, what
type/thickness aluminum sheet for the firewall to nosebowl longerons that the
door panels hinge on? Any construction hints or tips?

Thanks for any help,

Roger Hoffman #687R
Eugene, OR USA!

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rognal · Post by **rognal** » Sat Feb 18, 2012 9:05 am

Thanks Wayne and Ken. Your info will help me tremendously. Brian at Murphy
Tech is also sending me the instructions he has for their non-'speedcowl'
construction. So I should be well covered.

On another note, would anyone have a telephone number for the Warp Drive
Factory? The one I got from their Hoverhawk dealer was incorrect.

Thanks again,

Roger Hoffman #687R
Eugene, OR USA!

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Wayne G. O'Shea · Post by **Wayne G. O'Shea** » Sat Feb 18, 2012 9:05 am

1-800-833-9357 1-641-357-6000

----- Original Message -----
From: <rognal@dcsol.com>
To: <murphy-rebel@dcsol.com>
Sent: Monday, March 08, 2004 10:38 PM
Subject: Re: Rebel - Four Door Metal Cowling

Thanks Wayne and Ken. Your info will help me tremendously. Brian at Murphy
Tech is also sending me the instructions he has for their non-'speedcowl'
construction. So I should be well covered.

On another note, would anyone have a telephone number for the Warp Drive
Factory? The one I got from their Hoverhawk dealer was incorrect.

Thanks again,

Roger Hoffman #687R
Eugene, OR USA!

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