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Step 13: Install the Cowl:
You will install the cowl by cutting a hole in the cowl that is specific to your engine,
muffler and way you mounted the engine to the firewall. You will need the cowl, masking
tape, Dremel tool w/cutting disk & sanding drum, ruler, cowl mounting screws.
Locate Hole in Cowl for Engine Head:
It will be necessary to cut a hole in the cowl for the engine head to
protrude outside the cowl. Rather than guessing at the hole center, making
a small hole then gradually and iteratively enlarging it, GSRC will suggest
a more methodical approach using a paper template.
At the back of this assembly manual we have provided full scale
drawings of the two popular engines. Choose one, or use your engine’s
instruction manual which may have a line drawing of your engine. Enlarge
the drawing to full scale using a copy machine. (Shown left is a full scale
drawing of the OS-91FS 4/s engine.)
Cut a hole in the paper template about 1/8” outside the outer dimen-
sions of the head and place the template hole over the engine head. Itera-
tively adjust the hole size for good head clearance. Tape the paper tem-
plate in place on the fuselage.
Transfer Template Pattern to Cowl:
Fold the template back, out of the way at the tape point, and remove
the engine. Place the cowl back on the fuselage and measure the distance
from the firewall front surface to the front outside cowl edge to be 5-7/16”.
Secure the cowl with masking tape. You will have to notch the cowl area
where the nose gear extends into the cowl. Be sure the cowl is relative
straight.
Lay the template back over the cowl and trace the hole opening onto
the cowl surface using a felt tip pen.
Check Tracing:
Fold the template back and forth to check the traced line to be accu-
rate within the template hole.
Notch the cowl for nose gear clearance:
Make a notch (3/8” wide x 1.25: long) in the cowl bottom for the
nose landing gear.
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