Oil Filler Access Door

 January 8 2021

The oil filler and dipstick access was started by making a Splash coat of  3 layers of carbon fiber and then laying that onto the top surface of the engine cowling.  I identified the location and size of the door, marked it on the cowling with a sharpie and taped over area with packing tape.  This was left to harden for a couple of weeks while I did other jobs.  I spoke with a friend who builds Vans RV's on the field and he suggested I build a hidden hinge style for better esthetics.  I was happy to go this route and had a great example in one of his planes to model mine upon.  The splash coat is to form a new oil door from that is a perfect match to the curvature of that location of the cowl.  I removed the splash coat and then carefully cut out the shape of oil door I wanted.  Then I cut and trimmed the Carbon splash coat to exactly fit the door opening I just made.  I taped the inside of the oil door in packing tape then taped the new door into place on the outer surface of cowling.  I then made up fiberglass strips for flanges and applied to the sanded inside surface of cowling, these will support the oil door.  Afterwards trimmed down the flanges and installed the 2 Milspec quarter turn fasteners which will it closed.  I then bent up the aluminum curved hinge adapter out of .062 thick aluminum.  Trimming off the excess aluminum (right hand edge in photos) to get a good fit, finally drilling and cleco in place.  I am only riveting the outer ends of the piano hinge and other holes all have a dab of structural adhesive.  The hinge onto the adapter will have 5 rivets.