I finally got the top of the engine cowl fair. Before I cut the oil access door, I’m going to join the upper and lower cowl at the rear. First area around the openings for the prop and air are cleaned up.

Then duct tape is applied to the inside of the bottom half and the top half is sanded. The two cowl halves are installed and clamps are used to hold the rear of the cowl together. Then a five BID layup is used to create a flange on each side of the prop opening.

Once the layup has cured, a hole is drilled that will hold the two halves together and the manufacturing flange is cut away. Then the gap between the two halves is filled.

After filling and sanding are done, the air outlets are cut down to their final dimension. Malcolm suggested using 3/4″ masking tape on the step which provides a 3/4″ line.