OK, time to cut a cowl. There is nothing I hate worse than going to the field or an event and seeing a nice looking neatly assembled plane with a bastardized cowl. So I'll drop a few tips to try to help those of you that use a dremel tool with your eye's closed (you know who you are :nodding-yes-by-a-ve). Seriously though it's really easy with a couple of tips and the right tools.
1 - Put masking tape anywhere you are going to cut. It gives you a place to draw your cutout, and even if you draw your cutout on the inside he helps keep paint from chipping.
2 - In addition to "measure twice and cut once" you also want to make your main cuts smaller and work up gradually. Cut inside your lines by at least 1/8".
3 - The other best tip I have is to do any final sanding with some sort of tool. It can be anything, I have an assortment of wing tube scraps, cardboard tubes, even a sharpie or glue bottle. Anything but your fingers because there is no way to sand a straight line or a smooth radius with your fingers.
4 - Repeat after me......."I will not freehand cut my cowl"!! Draw an outline first!!
5 - One other thing to keep in mind, never cut a square corner. All stress is focused in the corner and the cowl will eventually crack.
I start with a carbide bit (shown in pic) to rough out the opening and then follow with a sanding drum, followed with some sort of "tool" with sandpaper to hand sand the opening.
Here are a few pics, a couple were marked from the inside and a couple from the outside:
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