We sanded off the micro balloon/epoxy filler at base of wind screen and were pleasantly surprised how easy this mixture was to sand into the proper profile. The profile looks good but we had a few gaps so we mixed up more and applied it as is seen in Image #1. Tomorrow, we should be able to sand this down and maybe cover the fairing with a layer of "raw" epoxy. The manual says that we will need at least 3 layers of epoxy before we finish on the fairing around the wind screen. We then put the top cowling on as is seen in Image #2. I LIKE the profile of our cowl, wind screen, and canopy, don't you? We then tried to put the 2 halves together but we found that we had to cut off the flange on the lower cowl. Drawing #45 Section A-A shows a definite flange to cut away and a molded edge but on our lower cowling there is NO flange so we progressively cut the sides back. We still don't have a good fit at the air intakes but the cutout for the prop is already round. I will call Van's today and see what they say. We will, with the help of Keith Thompson, our friendly A&P, put the prop on so that we can continue to fit the top cowling and then work on the sides again. I looked back and 1 year ago today we were struggling to install the landing gear mounts to the spar box. It is amazing how much has happened since then.
