User Manual

❏ 4. Mark the center of all four mounting blocks with
a pen. Lay a small ruler on the fuselage with one edge over the mark. Use a felt-tip pen to draw a line directly on the fuselage along the ruler. Mark another line on the fuselage 2-1/2" [65mm] as shown from the center mark on the mounting block. When the cowl is in place the lines and measurements will pinpoint the center of the blocks under the cowl.
❏ 5. Mark the remaining three cowl mounting blocks
and the fuselage the same way.
❏ 6. Slide the cowl over the engine onto the fuselage. Use a Dremel tool with a cutting bit to trim the cowl where necessary so you can get it to fit over the engine. At this stage the cowl shouldn’t require much trimming since the carburetor and muffler have been removed.
❏ 7. If necessary, use a prop reamer or the
appropriate-size drill to enlarge the hole in the prop for the crankshaft (or propeller bolt).
❏ 8. Temporarily mount the spinner backplate and
propeller to the engine. Mount the spinner cone to the backplate with the 3mm screws.
❏ 9. Use tape or have an assistant hold the cowl in
position. Be certain to provide clearance between the cowl and spinner—1/8" to 3/16" [3 to 5mm] should be adequate. Also be certain the checkers on the top of the cowl are centered on the checkers on the top of the fuselage.
❏ 10. Mark the cowl 2-1/2" [65mm] from the mark on the line indicating the center of one of the cowl mounting blocks. Drill a 3/32" [2.4mm] hole through the cowl into the mounting block inside. ❏ 12. Temporarily fasten the cowl to that mounting
block by partially installing a #4 x 5/8" [16mm] screw. Drill the rest of the holes the same way.
❏ 13. After all four holes have been drilled, remove
the cowl and enlarge the holes in the cowl only with a 1/8" [3.2mm] drill. Mount the cowl with the screws.
❏ 14. Remove the spinner, prop and cowl. Wipe the
alignment marks from the fuselage using one of the small paper towel squares dampened with alcohol.
❏ 15. Drill a 1/8" [3.2mm] hole through four of the
supplied 1/16" x 7/8" [1 x 22mm] round, plywood cowl reinforcements. Align the hole in one of the reinforcements over the hole in one of the cowl mounting blocks as shown in the photo. If necessary, trim the aft edge of the cowl reinforcement so it will not interfere with the fuselage when glued inside the cowl.
❏ 16. If necessary, trim the remaining three cowl
reinforcements the same way.
❏ 17. Roughen the inside of the cowl around the screw
holes. Add a dab of petroleum jelly or a drop of household oil to the threads of four 4-40 x 3/8" [9.5mm] screws and 4-40 nuts. Glue the cowl reinforcements to the inside of the cowl using the screws and nuts to hold them until the epoxy hardens.
❏ 18. After the epoxy has hardened, remove the
screws. Redrill the holes with a 1/8" [3.2mm] drill, then mount the cowl with four #4 x 5/8" [16mm] screws, #4 flat washers and #4 lock washers. Mount the spinner and prop to see how it all looks.
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