Using coats of various sanding sealers and primers, the foam shape of the intake cowling is made to have a relatively smooth surface.

When the surface is smooth and the shape is generally O. K., a skim coat of body filler firms it up after which, another coat of primer is added and sanded smooth.

Since the block of foam can't be easily fitted to the cowl for measuring, we make a mould of the piece by coating it with release agent and fiberglass.

Here you can see the fiberglass separating from the plug (only after it has fully cured, of course).

This is the "finished" product.  We'll work with it until we get much closer to final when we can make a piece from this mould. 

The outside of the piece is cleaned up and the fiberglass overrun is cut away.

Checking the fit to the cowling cutout identifies areas where work is needed, but not yet.

By forcing a round jar into the nose, a clean circle is achieved.  We need a perfect circle.  Fiberglass is used to build up edge strength and uniformity.  We let it cure...

Previous Day | HOME | Next Day