[Dig it]

Wow, I didn't even know they made 1/32 ply. I think out of the suggestions presented, that seems like the idea that would soot me best. Thanks for the info. I'll let ya know how it works out.

[Frequentcrasher]

No problem Dig it! By the by, they make ply right down to 1/64th but it's a little too thin for this fix. Your local hobby store should be able to hook you up with both the ply and the fiberglass. Any do it yourself store or autobody shop will have polyester resin. It does take awhile to cure, but I find it's worth the wait. Good luck and let us know how it turns out!

[Ejiro]

Originally Posted by Frequentcrasher

Those SU-26 cowls are quite long already, so I don't think anyone who matters would notice if you tacked on on an inch or so. Here's what I did in a similar situation. Cut a four inch strip of 1/32 ply. Clean the inside of the cowl with acetone and epoxy or CA the strip to the rear inside of the cowl leaving the space you need for the extension. Then cut a strip of heavy fiberglass wide enough to overlap the ply. The edge of the fibreglass should be cut as clean as possible, but a few frays are inevitable and are not the end of the world. Pull the fiberglass through some epoxy or poly resin ( I used a paint tray), then lay it over the ply, as close as you can get to the original part of the cowl and overlap the ply at the rear. You may have to make a few cuts to get it to round over the back nicely. Do as many layers as you need to to bring it up to the thickness of the original. Probably 2-3 will do, depending on the fiberglass thickness you use. Sand til you're happy with the finish coat. Now take drywall putty and fill the little space between the original cowl and new fibreglass. When the filler is dried and sanded, soak it with some thin CA. Be aware, however, once it's soaked it's like a rock, and very difficult to sand. Drill holes for your original cowl screws and you're ready to paint! You can reinforce the ply on the inside of the cowl by laying a strip of fiberglass over the edge that's inside the cowl, I haven't found it necessary, but it's probably a good idea. The extra 1/32 of space taken up between cowl and fuse isn't much trouble unless your cowl is extremely close fitting. In fact, it improved the fit on my cowl.

Good luck!

Brilliant!!!