AIRCRAFT MANUFACTURING / FIRST-YEAR TEAM PROJECT

From sheet metal
to a cowl flap.

A Piper Seneca 2 manufacturing prototype that connected material selection, forming, assembly and finishing.

My first-year team project provided practical exposure to the work behind a physical aircraft component. The report records the build sequence and the specialist workshop support used along the way.

See the manufacturing sequence ↓
White finished cowl-flap prototype on the workshop bench
THE FINISHED TEAM PROTOTYPE / ORIGINAL REPORT PHOTOGRAPH
Material in the report
Aluminium 6061 sheet
Project type
University team prototype
Supporting evidence
Report, build photos & five CAD part files

01 / MANUFACTURING SEQUENCE

A connected set of workshop decisions.

01 / FORM

Shape the panels

The team compared forming approaches and selected hammer forming for the embossed upper panel, considering practicality and cost. Other sheet parts were cut and bent to shape.

02 / CONNECT

Build the assembly

Hinges, connecting rods and linkage parts were prepared through drilling and lathe operations. Rivets joined the panel halves and hinge connector. The report also records specialist-supported GTAW work on linkage parts.

03 / FINISH

Prepare the surface

Grinding and filler addressed surface condition before the reported heat-resistant finish was applied. The build photographs retain the sequence from unpainted assembly to finished prototype.

Unpainted cowl-flap prototype assembly showing the formed metal panels
ASSEMBLY BEFORE PAINT / ORIGINAL BUILD PHOTOGRAPH
Close view of the prototype hinge and riveted panel connection
HINGE AND RIVET DETAIL / ORIGINAL BUILD PHOTOGRAPH

02 / PRACTICAL LEARNING

Learning through manufacture.

My contribution was as a member of the student project team. The evidence supports experience with the manufacturing sequence, coordination around workshop access and the relationship between formed parts, joints and assembly.

The project record includes the manufacturing report, original build photographs and five SolidWorks part files.

03 / SCOPE AND NEXT STEP

A prototype with a clear boundary.

This project demonstrates academic manufacturing and assembly experience. It does not establish flight installation, airworthiness approval, cooling performance or a production-qualified part.

Proposed future active control

A separate “future modifications” document proposes sensors, an ECU, actuation, feedback and manual override. This remains a concept: completed control hardware, flight integration and measured efficiency improvements are not evidenced.

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Source: supplied team manufacturing reports and original build photographs. Academic work; no manufacturer affiliation or endorsement is implied.