A Bodgers Solution to New?Damaged Cowls

[Stuphedd]

I have seen many questions on "How To" appertaining to cowls and canopies.

I refurbish many planes and end up making or repairing the above , so This is a very crude demo of roughly what I do ,

I started last night and did a bit this afternoon so its a bit rushed with little finess but it should show the idea ,

I have been rebuilding a very old , "old timer " which had a severe attack of wood worm , the cowl had been lost years ago so I mocked one up out of cardboard .

The procedure,

Make a rough item of what you want to make ,

get a plant pot or container big enough to house the item and pack wet sand round it

Move it about a bit and remove the "item" leaving a female mould

mix some very sloppy plaster and carefully fill the mould

let dry overnight

take out the plaster cast and carve it to the required shape , It carves dead easy "

When its ok and fits the model , Put it in a bottle and heat shrink/

Job done ,

I only had one bottle left so its a bit "rough " have to wait for the kids to come for replenishments !

I have used this sand method for repairing large cowls by making a mould with whats left of the original and carving the missing bit out of plaster , its very cheap , and fibreglassing a repair .

[Stuphedd]

more photos

[edgar]

Thanks Pete, very timely for me, I was just about to buy a new cowl but I'll have a go at this instead.