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When installed, the cowling will fit around the narrow
plywood cowling mounting ring and butt up against the front of
the fuselage. Carefully measure and mark the portion of the
cowling that must be removed to clear your engine's cylinder
head, muffler and carburetor.
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Carefully make the cutout, using a rotary tool with first a
cutting disc and then a sanding drum. Work slowly, checking
the fit often, so you don't remove too much of the cowling or
damage it.
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Slide the cowling over the engine and onto the fuselage.
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Line up the front of the cowling, using your engine's drive
washer as a guide. When aligned properly, the cowl ring should
be centered around the drive washer and the back edge of the
cowling should butt up against the front of the fuselage. The
front of the drive washer should be about 3/32" in front of the
cowling, too, to allow space for your spinner backplate.
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IMPORTANT
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Before cutting out the cowling to fit over your engine, notice that the cowling has a top and a
bottom. The bottom of the cowling is straight and the top of the cowling is angled down to match the angle of the top
of the fuselage.
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When satisfied with the alignment, use pieces of masking tape to hold the cowling securely in place and aligned.
STEP 2: INSTALLING THE COWLING
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With the cowling held firmly in alignment, drill 1/16" diameter
pilot holes into the cowling and through the cowling mounting
blocks for the three wood screws, making sure that you drill the
holes 3/16" in front of the back edge of the cowling.
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IMPORTANT
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The cowling mounting block on the left
side of the firewall is located approximately 3/4" below the
seam of the black covering material.
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If you drill the holes farther forward than 3/16", they may
miss the cowling mounting blocks.
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Remove the cowling and enlarge
only
the holes in the cowling, using a 5/64" diameter drill bit.
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IMPORTANT
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Enlarging the holes will prevent the fiberglass from being cracked when you install the wood screws.
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To strengthen the holes in the cowling mounting blocks that the wood screws will thread into, carefully apply a couple of
drops of thin C/A into the holes and let it dry completely before installing the cowling.
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Slide the cowling into position and realign it. Install and tighten the three M3 x 6mm wood screws to hold the cowling
firmly in place.
Continued On Next Page
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