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Old 10-24-2006, 07:19 PM   #1
Wayne 1
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Cutting Cowl ?

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Here we go my first attempt at cutting a cowl.I am putting together a Aero-works 46-61 Edge.The engine is a Satio and i am just fitting the clear plastic template much room do i leave around the valve covers and muffler,i was thinking 3/16 around valves and 1/4 around muffler?I have 2 hrs into this, cutting and fitting and want it looking right.Another question lads i will need to install a remote glow,should i install next to the Kwik fuel fitting,or the other side of plane.Your thoughts please Thanks Wayne
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Old 10-24-2006, 08:18 PM   #2
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Don't forget to cut out a large outlet hole. It should be at least 1/2 - 2 times the inlet to allow for hot air to escape. 1/4 inch around the muffler should be ok. Do not leave square edges, round everything to prevent cracking. A little CA on the cut edges will seal up the fiberglass and prevent delamination. On my planes I drill slightly larger holes for fuel dots. etc and then put a little silicone on the part to dampen vibration.
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Old 10-24-2006, 08:33 PM   #3
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Cutting Cowl

Best way to cut cowls is to use the round headed dental drill type thingy (?) that comes with your Dremel tool set.

Drill bits are not good for drilling fibreglass, as they induce cracking. If you use the dental bit thingy, you can cut freehand to very close tolerances without worrying about cracking or chipping.

I'm not at home or I'd post a picture of the bit I'm talking about.

Give it a try, you'll never dfo it any other way when you see how easy it is!!


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Old 10-24-2006, 08:38 PM   #4
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I've seen 4 strokes with less than 1/16" clearance for the valve covers. Looks good, but my hands shake so much I usually just leave the cowls off!

It takes me months to cut a cowl. Literally.
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Old 10-24-2006, 08:41 PM   #5
Wayne 1
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Right on,i forgot about about an air outlet i cut to close to the muffler,i will open it up back of the muffler some more.I have been using a small Dremmel sanding drum for corners and will use it on the painted cowl.
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Old 10-25-2006, 03:54 PM   #6
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I picked up a carbide ceramic cutter at home depot. It is for their rotary saws and fits the dremel collet. It is hanging over my work bench in a flexible shaft and used nearly every day while building. I finish the hole with a sanding drum as you do.
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Old 10-28-2006, 07:33 AM   #7
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Good idea to wear a dust mask too, after all, it is GLASS dust.
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