3 Piece Boot Cowl - A Handy Design

Darrel Starr · Feb 21, 2012

For those of you building or planning to build a Super Cub or similar plane, I would like to recommend building your boot cowl in three pieces. The top piece rolls around the top of the firewall. The two other wrapper pieces slip under the top piece then meet at the bottom in the middle. Dakota Cub builds boot cowls of this general description. Husky boot cowls are in 4 pieces. If you design it to screw together with nut plates on the firewall, you can easily repair it or reach parts hidden underneath.
I really didn't think I would ever take mine apart but after a couple years of use, paint started to bubble around screws. The problem turned out to be a mistake I made when prime painting the parts. I first primed with self etching VariPrime, which is a dark tan, then sprayed over that with white PolyFiber Epoxy primer. I didn't properly prep the surface and the paint separated between primer coats.

It was relatively painless to unscrew the two boot cowl wrappers and the false boot cowl pieces also.

Since I wanted Bob Schefter in Fergus Falls to strip and repaint the parts and since his shop is off airport, having the parts in small pieces rather than flying the SC into Fergus Falls meant that he could use his paint booth and get a nice smooth dirt free surface.

Anyway, just one example of why I'm glad the boot cowl comes apart.
Also, imagine if the rear seat heater box needs repair, not a problem - just take off the right side boot cowl wrapper and have at it.

kevin · Feb 21, 2012

I second to what Darrel says. I made my boot cowl for my -12 too. Instead of using a 3 piece, I made a 2 piece using a pattern off the old one with posterboard. The top "saddle" piece will make the boot cowl easier to fit because instead of working with 2 big pieces, you are working with 3 smaller pieces. I realized this when I was trying to fit my boot cowl to the frame. If I have to take my boot cowl off the frame like Darrel has had to do, I will have to take my windshield off. For securing the boot cowl to the 3/8 channel, nut plating the channel is the way to go.

Every restorer has a "If I had to do it over again, I would do this different..." list. a 2 piece to 3 piece boot cowl would most likely be on my list.

Bugs66 · Feb 22, 2012

That's how I did mine. Very convenient.

SpainCub · Feb 22, 2012

Darrel, thank you for your contribution! I always take something away of great value with your posts! and great picture to back your explanation... that really helps us technically illiterates.

Darrel Starr · Feb 22, 2012

Spaincub, thanks for your comment; Much Appreciated.

OLDCROWE · Feb 22, 2012

Wish Piper had done it that way...

kase · Feb 22, 2012

Just had a guy make one like that for my cub.
.

Dave Calkins · Feb 22, 2012

Darrell, a nylon washer under the screw heads will help keep your paint nice....Husky's have them......I put nylon washers under every screw on new paint on Cessna's, for sure, every one!

AkPA/18 · Feb 22, 2012

Another cub??? Looks good Alan!

Mark

kase · Feb 22, 2012

No just doing a little repair work. Started out with a craked tailpost. Ended up adding a 3 ft metal belly to the tail and a new boot cowl cause I didnt like the way the other one fit.

Darrel Starr · Feb 22, 2012

Dave, I do use nylon washers under all of the screws -- but the paint lifted anyway, no cure for a bad bond short of stripping it off.

tackdog · Aug 31, 2021

Hi Darrel,

I'm quite new to Supercubs and whilst waiting on a PA18 kit I've ordered, I'd like to buy a pan-box brake to make a 3 piece cowl and some smaller projects whilst building. What width do you think I'll need for the this cowl work? I'm currently looking at a 50" and a 36" unit.

Thanks

Gordon Misch · Aug 31, 2021

Darrel hasn't been on the site for a number of years, but I've been hampered by a brake / roll that is too small. Get the bigger one unless there's a good reason not to.

Steve Pierce · Sep 1, 2021

I have an 8' brake and a 6' press brake. The 50" will work perfect for most Cub work.

akwing · Sep 1, 2021

a four foot shear is handy - if you have no other uses it for it other than your cub project, it’s probably not worth it...quality tin snips work just fine.

wireweinie · Sep 1, 2021

Sheets of aluminum come in 4 foot by 8 foot and 4 foot by 12 foot. Get brake and shear that can handle at least the 48" distances.

Web

astjp2 · Sep 15, 2021

I have a Niagara rotary beading tool from about 1900 that I used to do most of my light joggle work, along with the 48" brake and 52" shear I also have a set of 1/4" bead rolls, which add nice stiffeners and edges. I still want to learn to do a wire roll. Good luck, Tim

Charlie Longley · Sep 16, 2021

I am looking at rebuilding my boot cowl. What’s everyone’s thoughts on the firewall, stainless or titanium?

astjp2 · Sep 16, 2021

Have fun with Titanium...

Steve Pierce · Sep 16, 2021

I have made several firewalls from titanium. Considerably lighter and I did not find it difficult to work with, just different. Drill slow.

skywagon8a · Sep 16, 2021

There are special drills for drilling titanium. As I recall they have a very shallow angle.

skywagon8a · Sep 16, 2021

See if you can notice the angle of the grind on the drill in the first two pictures. The third picture is comparing the titanium grind on the left with a "conventional" grind on the right.

The flatter grind cuts nicely through titanium. One of my first aviation jobs was drilling holes on the production line for Sikorsky. This flat drill is what we used for drilling the firewall on the top of the S-61 fuselage. I think it was Titanium? It was long ago.

stewartb · Sep 16, 2021

Charlie Longley said:
I am looking at rebuilding my boot cowl. What’s everyone’s thoughts on the firewall, stainless or titanium?

Given the choice a couple of times I’ve chosen stainless.

My EXP kit’s standard firewall was aluminum with fire-proof paint. I passed on that.

OLDCROWE · Sep 16, 2021

Charlie Longley · Sep 21, 2021

My boot cowl is in pretty good shape. Firewall not so much. I’ll probably order a Ti firewall from Atlee and just have them punch the holes I need.

is the hole in the picture for a defroster?

Steve Pierce · Sep 22, 2021

The fluted edge on the Atlee Dodge titanium firewall in a pain. I fit it on a Super Cub build several years ago.

Steve Pierce · Sep 22, 2021

I didn't like how the boot cowl sheet metal fit around the flutes and cut them off and used a firewall channel from Clyde Smith $85. https://www.cubdoctor.com/stainless-firewalls/index.html He makes a very nice set for reasonable money. Now I order my titanium from Titanium Joes ($200-300) and cut out my own firewalls. I have punches for the holes if you decide to make your own and want to borrow them. Compare to $768 plus shipping on the Atlee Dodge unit. https://fadodge.com/pa-18-titanium-firewall/

Steve Pierce · Sep 22, 2021

I used nut plates in the flange so the boot cowl can be removed in sections and used PRC sealant around the flange, front and back.

skywagon8a · Sep 22, 2021

Is the difference in weight between Stainless and Titanium really enough to compensate for the difficulty in working the material? What is the weight difference? Assuming the same thickness.

Steve Pierce · Sep 22, 2021

It is considerable but will have to look it up. I don't find it hard to work with. Shears fine, drills fine just slow down the drill and punches fine.

3 Piece Boot Cowl - A Handy Design

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