I had this problem with my 360.  I removed the top and botom cowing and mated them off the plane.  I found that on putting the left wire in it would pass on the side of the piano hinge.  To resolve this issue I sanded the Piano hinge area, mixed up flux and fiberglass, greases the wire and embedded the wire with the flux and fiberglass.  I let it cure overnight and pulled the wire out. I have never had another problem with the wire not lining correctly. I ended up correcting both sides so I would not have any future problems. The spacing before the fix was one half inch or less from the screw in to the Piano Hinge, just enought to cause problems as the "nut" was losened with use.  Putting the flux and fiberglass in tightened everything up.  Be sure that you grease the wire or you may have problems removing it.
Paul Hershorin
471LA

--- On Sat, 9/24/11, Robert R Pastusek <rpastusek@htii.com> wrote:

From: Robert R Pastusek <rpastusek@htii.com>
Subject: [LML] Re: Piano hinges and checking if....
To: lml@lancaironline.net
Date: Saturday, September 24, 2011, 9:05 PM
Ron wrote:

Today on my flight to Sebastian/FL I noticed on landing
that the wire that suppose to go through the piano hinges
(cowling) was sticking out on the side (not a pretty sight)

So I pulled it out and pushed it in again, it looked good
to me, and the cowling seemed ok, but when I can back home
it as sticking out.....again :(

So is there any trick I can use ? (it did not do any damage
and the wire was just hanging out at the side.

Ron, This is most often caused by the cowling halves and/or
fuselage join not being correctly mated before inserting the
hinge wire. (You didn't say where specifically you were
having trouble; some used this only for joining the top and
bottom; some used it in other areas.) It's important that
you trouble shoot this and correct ASAP, as the cowling
could easily fail and cause loss of the aircraft.

I can't offer much advice if the problem is with the
cowl/fuselage joint as these are all different, but the
top/bottom cowl joint is easier to troubleshoot, especially
if the hinge wire enters from the front of the engine (the
most common configuration).

If this is the situation you have, try re-mating the
cowling halves with the pin removed. Then carefully insert
the pin an inch or so into the joint, and look inside the
air inlet hole to see where it's going. You may have to
(carefully) push aside some of the baffling to do this. The
trick is to make sure the hinge halves are correctly mated
before starting in with the wire. Once you get the wire
through the first top and bottom pivots, it's impossible to
insert it any more into the hinge joint until they are
correctly mated--and aligned--unless one of the hinge parts
itself is broken.

So conduct a good inspection of the area to figure out
whether it's a broken hinge part or a mating issue and work
from there.

Glad to talk to you off-line if you want to give a call.

Good luck; this should be trivial to correct once you
figure out what's causing the alignment problem.

Bob Pastusek
703-271-8008



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