Great Planes Giles G-202 46 Kit - GPMA0238 - Manual (Page 37)

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1. Cut the cowl halves along the cut lines, then use a
bar sander to true all the edges. To check the straightness
of the edges, set the cowl half seams on the building board
to be sure it is straight and smooth.
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2. For now, the openings in the front of each cowl half
only need to be roughly cut out. Using coarse sandpaper,
“roughen” along what will be the seam on the inside edge
of each cowl half so the glue will stick.
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3. Join the two pieces together, using several pieces of
masking tape to tape across the seams.
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4. Rough sand the 3/4" x 18" ABS cowl mating strip on
one side so the glue will stick. Using medium CA, glue the
mating strip to the inside of the seam in the bottom of the
cowl. Cut off the excess and glue it in place along the inside
of the seam in the top of the cowl. Trim off any excess. Hint:
Be careful not to glue the cowl to the building board.
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5. Use a sharp hobby knife or a Multi-Tool with a
sanding drum to accurately cut the engine openings at the
front of the cowl.
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6. If the mating strips did not go all the way to the
spinner ring, reinforce the unmated areas with fiberglass
tape and medium CA.
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7. Slide the cowl onto the fuselage. Slide the spinner
backplate over the crankshaft and against the drive washer
and secure it in place. Move the cowl as necessary to leave
a 1/8" gap between spinner and cowl and to align the cowl
properly with the spinner. Note: If you are utilizing the O.S.
.91 four stroke or other engine in the top end of the engine
range, you may need to remove the valve cover and/or
needle valve to get the cowl to slide on without rubbing on
your engine.
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8. Hold the cowl in position tight against the front deck
sheeting and aligned with the spinner. Using the plans and
photo as a guide for location, drill the first cowl mounting
screw hole with a 1/16" drill bit. Fasten the cowl in place
with a #2 x 3/8" sheet metal screw.
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9. Confirming the proper positioning of the cowl for each
hole, drill the remaining holes and install the remaining
five screws.
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10. Remove the screws and the cowl from the model.
Drill out the pilot holes you just made in the fuse with a 1/8"
drill bit. From the 6" piece of white inner pushrod, cut six
1/4" lengths, making six cowl screw retainers. Push the
1/4" lengths into each hole until flush with the fuselage
side. Glue them in place with thin CA from the inside of the
fuselage. Note: These plastic retainers help keep the cowl
screws from vibrating loose.
Assemble the Cowl
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