Cowl inlet ramps:
1. Sanded the inlet ramp transitions.
Cowl seams:
2. Put the cowl on and off several times as I sanded and tweaked the seams between the upper and lower cowl.
Oil filler door:
3. Taped the door hinge to the cowl and tested its throw. Taped the door to the hinge, moving it around until I was happy with its placement. Decided to use a spacer under the hinge. Tried several sizes and placements before fabricating a 5" x 1.5" X 0.020" aluminum strip that worked well.
4. Located and drilled 5 rivet holes through the hinge. Clamped the hinge and spacer to the cowl, and used the hinge holes as a drill guide to drill the attachment holes in the spacer and cowl.
5. Removed the cleoces and deburred everything. Roughed the spacer and cowl with 80-grit sandpaper. Countersunk the rivet holes in the cowl.
6. Mixed up some resin and flox, Applied it with a small brush to the backside of the spacer, the clecoed the spacer and hinge to the cowl. Riveted the hinge and spacer.
7. Spread the flox mixture across the hinge and the cowl pocket in which it sits, essentially embedding it in a thick coat of resin.
8. Did some fit tweaks on the door itself, first bending the edges and then the whole door to get it to lay very flat against the cowl.