Installing AuCountry Jaguar Cowl on my AA5-B

This page is to document the steps I am taking in the process of installation of Jaguar Cowl.

The cowling is available from AuCountry Aviation - www.aucountry.com.

Hardware

The Cowling comes with the Installation Instructions which has a list of Tools and Harware reqirements, but I still had to spend many hours fuguring out exactly where to buy parts, how many and what exact sizes to order.

The following web sites helped me to figure it out:

http://bobmay.astronomy.net/misc/drillchart.htm - helpes to figure out the numbered drill bit sizes in relation to fractional rivet sizes.

http://www.hansonrivet.com/w06.htm - solid rivet installation guide. I haven't worked with solid rivets before. Notice suggested Clinch Allowance at the bottom of the chart. It helps to determine the proper rivet length.

http://www.afscamloc.net/xua/downloads/4002%20Series.pdf - CamLoc selection and installation instructions.

Here is my parts list:

1. Rivets to hold upper cowl halves to hinge - cherry-max countersunk head 1/8". 38 rivets - 19 on each side. Install manual asks for CR3212-4-2. According to Aircraft spruce <https://www.aircraftspruce.com/catalog/hapages/cherrymax.php> those have grip range 0.63 to .125. I measured hinge thickness + upper cowl thickness = 0.142". Maybe CR3212-4-3 is better? Ordered CR3212-4-2 anyway. Those require drill #30, Aircraft Spruce part 12-04217 and #30 countersink, Aircraft Spruce part 12-00880. The cage for countersinks is Spruce part 12-00940.

2. Nutplates to hold lower cowling halves together. 9 on the bottom + 3 on top. There are also 2 to hold upper cowling halves to lower cowling. Total 14. Install manual asks for MS21048-L-08. I believe Manual says 'countersunk' by mistake. I found those on www.cessnadirect.com. AircraftSpruce has MS21047L08. Aren't they the same?

3. Solid rivets to attach those nutplates, countersunk 3/26". The lower cowl joggle thickness measures between 0.07 and 0.09", the nutplate thickness is 0.035", so the total grip is between 0.105 and 0.125. The clench allowance for 3/32" is 0.094. So need Aircraft Spruce part AN426AD-3-3.5. Ordered 1/8 lb - a lot of rivets to practice on scrap aluminum. Require drill #40, Aircraft spruce part 12-04214 and #40 countersink part 12-00881.

4. Camloc part according to Install Instructions, except they leave out the Camloc receptacles, Aircraft Spruce part 214-16N. Those receptacles require 1/8" rivets. The receptacle plate depth is 0.091, the lower cowl joggle thickness is between 0.114 and 0.134, the 1/8" rivet clinch allowance is .094, so total rivet length between 0.3 and 0.32. Ordered Aircraft Spruce part AN426AD-4-5. Also need Camloc pliers, Spruce part 12-01475, although I used a cut split washer and Cleco pliers instead.

5. Rivet Squeezer, Aircraft Spruce part 12-01462, and two squeezer dies part 12-01466.

6. Clecos, Spruce part 12-01138. 12 to hold lower cowl halves together, 19 to hold the upper cowl halves to the hinge and 10 to hold the upper halves to lower cowl - 31 all together. Cleco pliers, Spruce part 12-10105.