| Step 1:
Hang the engine. Can't do the cowl mold if the engine isn't there, however,
some folks have done it that way. |
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| Step 2:
Bag it. Plastic and cardboard was used to wrap and
shield the engine from foam. Hope this worked! |
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| Step 3: Build
the box. Need some sort of box to contain the foam. Should have used formers around
the engine to guide the foam cutting. |
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| Step 4:
Pour the foam. 2-part, expandable foam was used to fill the box. Very
sticky. Stuff gets everywhere! |
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| Step 5: When
foam has cured, strip away box, mark the engine, and start cutting. The use of a
22" wood saw was finally used to cut away large sheets of foam. |
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| Step 6:
Mark- Sand -Mark -Sand. That's kind of the way it goes. |
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| Step 7: Cut
away too much. Put foam back on. Mark - Sand - Mark - Sand. |
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| Step 8:
Finally starting to look like the cowl. Well, one side anyway. |
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| Step 9: Where's
that prop. Funny looking color, too. "UV Bondo" was used to fill the
foam but that didn't cure well, so the old fashioned "Bondo" was used.
This was followed by a very light weight filler. Fill - Sand -Fill - Sand... |
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| Step
10: Getting close. After lots of sanding and sanding and filling and sanding
and filling and.... The cowl was split, and glass doubler bonded to split line.
Large cylinder cutout will be covered by metal panel. |
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| Step 11: Note oil
access door panel. After much thought about putting this somewhere else, it went
where the plans said it should. Door is yet to be installed but cut-out is done. |
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| Step 12:
Still working the cowl but it all fits together. All that's needed is more
sanding and some filler. |
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| Step 13: Note the
Inspection door on the top cowl half. This is not in the plans but the Webmaster
added it because of a lack of view into the rear of the engine without taking off the top
cowl. |
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