Removed the cowls, again the lower cowl slid off the bottom and between the lowere blades of the prop without even having to wiggle the blades. I measured the difference in the gap between the cowl and spinner using a caliper and the bottom is 1/8" closer. There's not 1/8" of fiberglass in that area, So.... I needed to reinforce (add fiberglass layers) to the inside of the cowl prop ring, so that when I sanded the lower portion to remove 1/8" there would still be fiberglass in place. I ended up cutting several 2" strips of glass on a 45 degree bias. Then I laid about 12 plys onto the inside of the bottom of the cowl ring. I staggers with smaller/shorter plys so as to 'taper' the buildup. I used the Fast epoxy from sticky stuff, and then put the halogen lights on it, it cured hard in 30 minutes. I rejoined the upper and lower cowls, and then used the 90 degree air grinder with a sanding disc to sand/grind down the lower portion of the lower cowl. I used a straight edge to find the high spots, and as best I could to get everything into the same 'plane'. Handed sanded everything w/ 60 grit. Then disassembled the halves and remounted the lower cowl to check the fit. Its' VERY close, but I think that I will remove aprox another 1/32" from the bottom edge of the lowere cowl and that should make it Perfect...... Monday's task.
Build up inside of cowl ring w/12 plys of 6 oz glass
