User Manual

16
Cut the Cowl
If going electric the cowl probably doesn’t need to be cut—just
skip ahead to “Mount the Cowl” on page 18. But if using a glow
engine the cowl must be cut to fi t over the head and cylinder. If
using an O.S. 1.55FS-a you’re in luck because we’ve provided
a template that can be used as a guide. If installing a different
engine you’ll have to fi gure out where to make the cut yourself.
Some modelers dread this process, but you can make it easier
and achieve great results by proceeding slowly and using
the proper tools. The best way is to cut in small increments,
fi tting and marking the cowl as you go. When you zero-in on
the fi nal shape of the cutout you can position the cowl more
accurately until you can make the fi nal cuts.
With or without a template, the most important thing is to have
the proper tools. It cannot be over emphasized how helpful a
Dremel carbide grout removal bit and a Dremel sanding drum
are for cutting a fi berglass cowl—these can be found at most
hardware and home-improvement stores. Initial cuts go easy,
fast and accurate with the carbide bit. Then, the rough edges
can be smoothed and rounded with the sanding drum. The 1/16"
carbide cutter and 1/4" sanding drum are absolutely a MUST,
but the 1/8" cutter and 1/2" sanding drum come in handy too:
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1. The cowl will be easier to start fi tting if you can remove
the head from your 2-stroke engine or remove the valve
cover from your 4-stroke engine. Also leave the muffl er off
the engine for now.
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2. If using the O.S. 1.55FS-a, cut the template from the
back of the manual and tape it into the cowl. The top of the
template aligns with the bottom of the cowl “cheek” and the
back of the template aligns with the back of the cowl. Use a
fi ne-point felt-tip pen to mark the cutout directly onto the cowl.
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3. If not using the template you will have to determine
where to mark and cut the cowl yourself. Position the cowl as
far over the engine as it will go. Use a lead pencil to mark the
inside of the cowl where it needs to be cut to clear whatever
part of the engine is in the way.
It’s time for cutting. Work in a well-ventilated area and
always wear protective gear including goggles or glasses,
hearing protection and an appropriate breathing fi lteration.
Also do your self a favor and wear a long sleeve shirt to
protect your arms from itchy fi bers that get into the air.
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4. Use one of the grout removal bits to start cutting the cowl.
If you’ve marked the cut with the template, cut approximately
1/8" [3mm] inside the lines. If you didn’t use the template, cut
where you made your fi rst marks. Note: The grout removal
bits work best and cut most accurately with the speed of your
rotary tool turned all the way up to full rpm.