Harry asked me to repair the fan cowl for the Nuffield, as it was rusted – that was an understatement – it needed the lower half replaced.
I cut away the rotten metal and made a new plate using the curve template of the upper instant section. The top of this original fan cowl has the outshot section at the top to allow you to fit the fan belt – new replacement cowls do not have this feature.
From my measurements, the cowl was 420mm in diameter, so I tacked the new flat plate in place at this measurement from the top section. My plasma cutter is out of action so used the angle grinder instead.
Next I cut a strip of flat tin 56mm wide and tack welded it at 90 degrees to the curved flat plate.
After I had it welded together, I used chemical metal to fill any small holes and rubbed it down flat.
Finally, I undercoated it with rust primer and finished it in Nuffield poppy red.
