Boot Cowling Ext Question

[FFTravism]

Not sure if this is a bearhawk 5 thing or newer kit thing. What has everyone done with the flaps on the rear of the boot cowl extension? I noticed on older kits the metal at Stn C just went straight without the flap pieces.
Thanks

 

[Ryan Koeneke]

After looking at it for too long, I just decided to cut them. I didn't see anyway to support those longer flaps and figured they'd just vibrate and chew up the fabric (I have no basis for this thought process but it's what I came up with).

​

 

[gregc]

I could be wrong, it has been a while, but I think if you have/use the boot cowl side extension aluminum pieces, then the triangular portion of the bottom extension give you a spot to join the two. Some folks just carry the fabric all the way to the door front and then it becomes superfluous. Here is an old photo from my log.

 

[FFTravism]

I was thinking about cutting it too. Never seen the side below the door extensions. Interesting idea. Thanks

 

[Battson]

This is correct

 

[Battson]

The under-door pieces come (used to come?) standard with the kit. I have them installed, and they connect to the triangle pieces.

You could certainly cut them off and have fabric under the door.

Having metal in these areas under the door sill might be desirable if:
- your passengers are exceptionally clumsy (this hasn't been an issue for me - they hit the sill and the struts with their feet, not the area under the window)
- you have a lot of wiring / etc behind which you might want to change / maintain in future

Here's a kit manufactured around 14 years ago


Here's an example of the wiring, fuel lines, which I have behind. The other side also has the static line.

 

[FFTravism]

Where does the fabric glue too with the side pieces still at the front former? I am wondering why you couldn't take the metal all the way to the back former?

 

[Battson]

Where does the fabric glue too with the side pieces still at the front former? I am wondering why you couldn't take the metal all the way to the back former?

You have to add a little piece of metal which runs from the sill to the longeron.

You can do this by just bolting on a piece of aluminium angle, shaped to fit around the interior fabric. I attached mine with an adle clamp at the bottom end, without rubber, and I used protective tape to protect the fabric, you don't see it under the metal.

A welded piece would be better, but you want to be careful welding to the longerons - it needs to be right.

I asked the same question - why not supply a larger piece and terminate the fabric further back? The answers were:

1. Lack of necessity - a larger piece would probably serve no purpose, the existing piece is optional already
2. Weight, fabric is much lighter

Photos to show the aluminium angle

 

[FFTravism]

Very interesting. Thanks for the pictures and insight.

 

[Nev]

See if some of these photos help, to add to what others have already said.

 

[FFTravism]

Thanks Nev for the examples.
Travis