Cockpit Faring - Part 1

Fairings are supplied for the cockpit sides with their locations and arrangements shown in the fuselage manual and the final arrangement is a builder preference.  See:  Fuselage Manual page 25

Factory faring dressed up

Factory Side Panels
The cockpit covers were installed by match drilling using the angle flange attached to the external skin as a template. 
[see image below]

The  instruction's show the fairings fitted under the angle but on this aircraft they will be placed on the top side to create a tidier finish.

Trial fitted the first factory panel [Item 2] and adjusted it to fit and if required trace the outer edge profile and dressed to fit as required. 

The faring was fitted under the side panel's mounting angle and two holes are marked using a felt tip pen, drilled and clecoed in position. All other holes were marked using a 1/8'' transfer punch and drilled off aircraft. 
[see image below]

Angle fitted to drill faring
See notes above

The hinges had been fitted previously as the starboard fairing has to be trimmed around the front hinge

Fitted the second faring, adjusted until a tight fit is achieved with the first then repeat process as outlined above. 

Repeat at the opposite side.

Co-pilot Fairings - Optional
This project is attempting to create the feel the Shorts Tucano so additional panels were manufactured using 0.012'' x 2024-T3 to match the factory covers and profile line from the pilots compartment to the baggage compartment bulkhead. 

The factory advised that when operating in a hot climate's additional air for the co-pilot is required. A custom ABS plastic inlet was machined and fitted to each side side panel to collect air and feed it into the third fairing shown opposite. The air flow is controlled by the adjustable vent's with surplus air vented by two fixed outlets locate at the rear of the third panel. 

Details will be outlined in a separate post.

Flaring Tools 
A series of lighting holes influenced by the prototype were added using suitable hole saws and to stiffen the panels flaring tool's were used.

The benefit to the panels is the stiffening not weight saving, its really just eye candy but help's reduce the hippy look of the panel line chosen. 

The kit shown was purchased from Ebay from FABPARTS 2009 and all worked well on the 0.012'' and 0.020'' aluminium panels.

Another brand chosen for the 2.5'' hole but stretched the metal and buckled a panel.

A replacement die from the original supplier was purchased to finish the faring's. These tools get a personal recommendation in aluminium - they just work even on painted surfaces.

Trail Assembly Port Side