Vintage Mooney Cowling Mod

[MyNameIsNobody]

Here's a few photos of the cowling prototype. This is the plug to make the molds. I need to have this finished in two weeks in order to make my May 31 deadline.

David

Here is my comment: I LOVE IT...I WANT ONE. Really pleased this is coming to fruition. Will this be metal or fiberglass?

[jamesm]

I may be to late in the game but I found  the  eninge cooling section of  this  video very interesting.

Consider the first part of this video on Pipsrel Panthera about engine cooling.

Seems like a  well thought out desgin.

 

James

 

[Sabremech]

Thanks Jamesm. Very interesting and gives me some things to maybe try as I fly mine and work out any issues before it goes to an STC.

I'm almost done with the major bondo work and should be putting the final finish with primer this week. My goal is to get it to the mold shop by next Saturday. Here's a couple of current pictures of the shape coming together.

Thanks, David

[MB65E]

Looks good Dave. How much of the old cowling will be removed under your new molded part?There is some significant gains in cooling regarding the lip on the air intakes. Rounded transition back to the cooling plentum etc. Will the inside portion of the inlets be shaped as well and or conform to the baffling? I would almost stop the mold line at the start of the carb/fuel servo air inlet. If you wanted to modify the carb inlet box you could make your new shape just a screwed on piece, much like it is now but a better transition similar to a Lancair 360/ RV 4 intake. This way you could sell the cowl modification to M20s A-G. The airbox would then be another part etc.

I like the overall simplicity. I know you were worried about the paint cracking when you attach fiberglass to the sheet metal. Cracking would be less with Carbon. I'm sure the first few will be glass due to cost.

If you need a spare spinner ring and spinner for some of the older spinners, let me know. I'd be happy to send my old one for planning purpose. I think you could sell a lot more "kits" if you could do all spinners that are on M20s. I'm not sure, just guessing, the spinner hole in the cowl would need to be opened up a bit maybe an inch?

Nice work!

-Matt

[Sabremech]

Hi Matt,

The top cowling will have the forward say 6 inches removed and replaced and on the lower cowl, almost all of the skin changed or riveted over the top of the original. That's yet to be determined. I stepped back from using a plenum for a couple of reasons, first it didn't fit well and I was going to have to modify it for a nice fit and secondly, I wanted to get rid of the square air filter inlet.

I'm currently planning on using an aluminum machined ring to be the smooth transition into the cylinders as James Aircraft is using. I'm going to machine them a little different for appearance to my cowling mod. The benefit to this is that I could go back to a plenum setup if cooling suffers.

I'm currently designing a new carb airbox to fit under the cowling and connect to the air filter that is planned to be mounted in the left air inlet. That's why I'm smoothing off the bottom of the cowling.

I'm not sure I could make my cowling mod work well with the old spinner as it sits further back on the prop and is a smaller diameter. Is that correct? The first parts are going to be fiberglass and I'll see how it all goes together on mine. I suspect there will be changes to the planned STC after I see how all this goes on mine.

Thanks,

David

[MB65E]

Makes sense to me! Good luck!!

-Matt

[dcrogers11]

I haven't been as excited about a prospective new mod to my C since the the 201 windshield upgrade.  I may have missed it in the thread, but if all goes well theoretically, when would you hope to be able to market your product given FAA approval process and then manufacturing the kit.

 

Please keep up the great work as I think you have a great prospective product for our wonderful birds.

 

Best regards,

Don

[Sabremech]

Hi Don, I anticipate it to take at least a year to get it to an STC and have kits available. I'm hopeful that I get some good speed increase, reduced cylinder temps and good looks out of this mod.

Thanks,

David

[dcrogers11]

Hi Don, I anticipate it to take at least a year to get it to an STC and have kits available. I'm hopeful that I get some good speed increase, reduced cylinder temps and good looks out of this mod.

Thanks,

David

 

Good deal, gives me time to start saving my pennies.  

Don

[Sabremech]

I've finalized the top cowling and what part is getting changed. Here's a couple of photos showing how much is going to be changed and the factory seam where the new piece will be riveted in.

David

[merrja]

Great Job David and good luck!

[Sabremech]

For anyone going to the MAPA Homecoming, I'm going to try to bring with me some cowling parts to show anyone who may be interested. I'll be getting into Kerville on the 14th. Look forward to meeting all who attend.

David

[dcrogers11]

Will be at MAPA.  Look forward to meeting you and seeing the fruits of your labor.

Don

[Sabremech]

Putting some detail work into the cowlings. Closing the gap between the pieces and shaved off the button head rivets for a smooth panel for the lower cowling. I think most of the lower cowling skin is going to be replaced. It will rivet to the original stiffeners and reinforcements with countersunk rivets for a nice smooth cowling. I still need to add to the spinner circumference as someone suggested in case of engine sag over time that there's no gap to grab more air or look unsightly.

Thanks,

David

[jamesm]

Hi David,

Is the landing light  lens cover  part of your  mod?

 

Thanks,

James '67C

[Sabremech]

Hi James,

It could be as they're inexpensive to make. I'll consider putting it in.

Thank you,

David

[MyNameIsNobody]

That is a good idea. Plexi is cheap. STC was $100 or so for landing light cover...

[Sabremech]

I finished my work on the cowlings and delivered them to the mold shop today. They're going to clean them up and I'll go back up in a couple of weeks to give the final ok before making the mold. It's going to be close, but I'm going to try to have cowling parts to bring with me to the MAPA Homecoming. Everyone is working to meet that deadline.

Here's a couple of pictures of the cowlings as I dropped them off today.

Thanks,

David

[Hank]

Dang, those look good! I'm busy fantasizing about a chinless C model . . . Any way to add the missing 20 hp while keeping the easy-to-start, stone simple O-360 so we can surprise some E owners?

[MB65E]

Looks really nice Dave!! I might need to find a 201 spinner when it's all said and done.

What will the first run be S-Glass or something like that? I can't stand the chop glass Lasar and som other mod folks uses on their parts, it's really heavy...

Keep kickin!!

-Matt

[Sabremech]

Thanks guys, the first two sets of parts are going to be fiberglass. The shop knows about the weight issue. Mike Ellilott gave me the name of a shop that does carbon fiber somewhat near me, so the production parts may go that way if the cost isn't crazy. Stay tuned.

David

[flyntgr1]

Keep in mind that if you go carbon, you will probably need carbon molds as well.

[MyNameIsNobody]

I finished my work on the cowlings and delivered them to the mold shop today. They're going to clean them up and I'll go back up in a couple of weeks to give the final ok before making the mold. It's going to be close, but I'm going to try to have cowling parts to bring with me to the MAPA Homecoming. Everyone is working to meet that deadline.

Here's a couple of pictures of the cowlings as I dropped them off today.

Thanks,

David

image.jpgimage.jpg

Winner!

[DaV8or]

I'm confused. I thought this was for a C, right? Where's the air intake? Is that some thing you will cut out a hole and mount after the part is made? Looks great BTW! Love to see it on the plane.

[Sabremech]

Yes, this is for a C&G. The air intake will be in the left cylinder air inlet with a duct down to a new carb airbox. With the STC kit, there will be two new cowling pieces, all new baffling, landing light cover and a new carb airbox. The spinner will be provided if needed or it can be purchased separately by the customer on their own.

 While the cowling parts are being made, I'm back on to the baffling with the new air filter mounting and ductwork as well as making the new carb airbox. Hopefully everything comes together for installation the last two weeks of May with test flying starting in June.

 Thanks,

 David