I figured I'd follow up my original post with the results from a shop I learned about that ended up being right in my own back yard.

I got in touch with Deason Aircraft Services out of Paola, KS last summer and flew the airplane down to have them take a look at the cowling. Don (Deason) was optimistic about how much of the existing sheet metal could be salvaged or repaired, and we set up a time over the winter to get the airplane in for some TLC.

Since the original pictures were taken, the massive blob of bondo that someone had smeared on the chin of the cowl was starting to crack around the edges. In fact, it was a round patch about the same size of the bird strike ding in Mudwagon's picture, but not quite as deep and located square under the air box location. I originally thought the damage was from a ground loop at some point during the life of the airplane, but now that I've seen the inside of the sheet metal part and compared it to Mudwagon's picture I suspect our airplanes shared the same fate.

Don fabricated a completely new center skin that starts just below the air filter and goes all the way to the aft edge of the cowling between the cowl flaps. He drilled out all the other loose rivets and cherry max rivets that had been shot in the cowling over its life and replaced them with new rivets. He cut out a scabbed-on surface patch on the left lower cowling skin and fabricated a flush patch for that hole.

When I picked the airplane up he showed me the original center skin, and I'd guess it weighed 5 pounds with all the bondo that was smashed into it (that front ding wasn't the only place that had bondo). I wish I'd saved that skin just for a conversation piece.

Deason also replaced the cowl flap hinges while he was at it. The whole repair took a little longer than expected and cost a little more, which I was prepared for. When you're dealing with hidden damage, you know the problem will only get worse once the paint is stripped off and rivets drilled out.

Deason was able to salvage the rest of the skins and then had the lower cowling painted to match the top cowl. They did a fantastic job and I'm happy with the end product.

The pictures below don't do the work justice, as I didn't take them with the detail I took of the "before" pictures.

If someone needs a referral, I'd recommend https://deasonaircraft.com/ without hesitation.

-Slip

Great post and thanks for the info!!!!! It does look like a quality job. I think a new carbon fiber from Selkirk is over $10 grand and have no idea how the fit actually turns out. Would be interesting if anyone has first hand experience.

Slippery Wing wrote:That's impressive, Mudwagon. That's exactly what I'm looking for. Those tradesmen that are masters in their craft and can build anything.

Not taking anything away from Beegles, they're good and if I was into anything structural I would lean on them more.

I'll give David a call, Upnorth. One thing I learned buying my airplane and having some pre-buy work done by Beegles is that freight can be a significant cost to consider. Foley, MN is a bit closer to KC than Montreal and would be cheaper to ship (or I could fly there and leave the airplane if needed).

Go visit those folks first. I don’t have personal experience, but one of the really busy outfits in that part of the world won’t take Cessna parts to him any more. Problems getting paperwork I was told. They’re going to a gent in Embarass, MN, now. He re skinned an aileron for me, great work, on time and lots of paperwork.

MTV

Does anyone have experience with the knots2U carbon fiber cowlings? McFarlane is distributing them. And they claim they are PMA with an STC for the 180-185, and are 30-40% less weight.

https://www.knots2u.net/categories/cess ... lings.html

The 3 lower cowling skins (left, center, right) are listed on the McFarlane catalog (no price), along with the left, right and top access doors.

https://www.mcfarlaneaviation.com/artic ... ts-180182/

By my math, a carbon fiber cowling, with reusable hardware and brackets from your old one is about $7,800. Tack on another $1,100 for two new (if needed) access doors.

It ain't cheap, but neither is paying a skilled tradesman to re-make aluminum skins with an english wheel.

Thoughts? Curious about the weight savings, too. 30% of 15lbs for a complete upper and lower cowling is 5lbs weight savings - off the nose.

180Marty wrote:Great post and thanks for the info!!!!! It does look like a quality job. I think a new carbon fiber from Selkirk is over $10 grand and have no idea how the fit actually turns out. Would be interesting if anyone has first hand experience.

I put a Selkirk cowl on my Wagon. The fit was amazing, I was completely done, minus paint in 8 hours. It wasn’t cheap, but my cowl was pretty rough. It looks perfect now.

FWIW here's a link to the Selkirk website.

https://selkirk-aviation.com/cowlings/

Looks like a (pretty much) complete set-up for my 1953 model is $9432.
Selkirk sez "composite", they don't specify fiberglas, carbon fiber, or just what.
They do say no significant weight difference from stock cowlings.
I think I'd be more concerned about durability than weight--
lighter is not always better.

hotrod180 wrote:FWIW here's a link to the Selkirk website.

https://selkirk-aviation.com/cowlings/

Looks like a (pretty much) complete set-up for my 1953 model is $9432.
Selkirk sez "composite", they don't specify bfiberglas, carbon fiber, or just what.
They do say no significant weight difference from stock cowlings.
I think I'd be more concerned about durability than weight--
lighter is not always better.

Mine was carbon fiber. It feels about the same weight, take that for what it is, as an original cowl. The durability is good in my opinion, seems very strong to me. Way easier to repair if something goes sideways.

Here’s my Selkirk cowl

Thanks for the pictures!!!!! That looks super.

185er wrote:

Very nice, the other Selkirk cowls I've seen are very nice also.
I like your gill covers.

So glad I found this thread as I am in need of some cowling repair for my A185F.

Had an incident at a small grass airport in Maine while taxiing. Ran into a newly installed Frisbee Golf chain net thing on what had been used as a taxiway. Wings removed and was taken to my mechanics hanger 50 miles away with the engine and prop off now.
I am working with the insurance adjuster which has been very helpful and not haggling over estimates.
Reading the posts here has given me a couple of outfits to contact.
Just wondering if anyone has any thoughts where the best place might be to send it?
Tom

That's a bummer, Tom.

As mentioned in my post, I had really good results using a local sheet metal guy. One thing to consider is whether or not the fabricator would need your cowling on the airplane or whether he can fabricate the skins for the cowling without the rest of the airplane. It will likely depend on which skins need to be replaced, but it will make a difference in logistics.

Beegles is always worth a phone call.