To get the carbon fiber airfoil over nose gear shock to fit in the cowl and still have room to remove the cowl with the prop on, I ended up with a slot 70mm wide by 240mm long. Marked a 35mm diameter half circle just inside the prop end of the 70x240mm rectangle. used a 2 3/4 inch hole saw (slightly smaller than the 70mm) to cut this hole. Then used a Dremel diamond coated disk to cut the remainder of the 70mm wide slot to the back of the cowl. Used a sanding disk on the Dremel to sand to the line of the 1/2 circle. Used a razor blade to cut the insulated foil 1/16" back from the edge of the slot. Used a sanding stick to sand the straight portion of the slot smooth and put a chamfer on both side to get rid of rough edges and prevent gelcoat chipping. Wrapped sandpaper around hole saw and used that to sand the 1/2 round hole in the slot.
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