This is a big messy project that ruins tools. I have fiberglass dust all over the shop and cutting and drilling fiberglass ruins band saw blades, drill and countersinks. The results were very good, you just have to take a lot of time and cut and sand slowly until the gaps a perfect. This is a place the really shows after the plance is painted if done poorly. I cut the aluminum strips to 7/16" from .025 sheet and cleaned them up on the Scotch Brite wheel and after sanding the inside surface of the fiberglass tip, epoxied them in place using side clamps. The end piece on the nose tip is Dynacel foam which I'll cover with 9 once glass cloth and then I'll fill the pops and seams with Super-Fil. This was a lot more work than I thought it would be, so, I can imagine the cowl will take a long, long time to mount properly. After building RC Models for years and seeing how close tolerances can be with glass parts, I'm a little surprised they fit so poorly. I hope the cowl is better since it is epoxy vs. gel coat polyester.
