Top Flite TOPA0120 - Manual (Page 43)

❑ 4. Test fit the taped together parts on the
fuselage. Trim the cowl parts as necessary for a
better fit.
❑ 5. Tack glue the cowl halves and cowl front
together. Remove all tape and finish gluing all
parts together.
❑ 6. Place the cowl on the fuselage and check
the fit. Finish trimming the perimeter of the cowl so
it fits well on the fuselage.
❑ 7. Sand the entire cowl with #220 grit
sandpaper. The glossy finish on the plastic parts
must be roughed up slightly to allow the filler and
primer to stick properly.
❑ 8. Use “BONDO ® ” (Automotive Body Filler) or
a filler of your choice to fill the seams of the plastic
parts. Keep the amount of filler to a minimum
because of weight.
❑ 9. Cut out the three recessed Air Intake Ports
in the cowl front. These ports must be open to
allow air flow for engine cooling.
❑ 10. Trim the vacuum formed Cowl Flaps.
Make sure you begin by trimming approximately
1/8” outside the finished trim line.
❑ 11. Place the main cowl on the fuselage and
tape in place. Hold the Cowl Flaps in place and
mark both sides to match the fuselage sides.
HINT: Align the cowl flaps to the main cowl with
the center recessed area on the cowl flaps
centered on the seam of the main cowl.
❑ 12. Glue the Cowl Flaps in place when they
are aligned with the fuselage.
❑ 13. Sand the inside of the Cowl with a coarse
sandpaper to roughen the plastic so epoxy will
adhere. Clean the inside of the main Cowl with
alcohol to remove all dirt and sanding dust.
❑ 14. Apply the strips of Fiberglass Cloth
(provided) with 30-minute Epoxy to reinforce all
internal seams and edges of the cowl assembly.
❑ 15. Spray the finished sanded cowl with a
sandable primer. NOTE: It is very important to use
a primer that is compatible with the type of paint to
be used for the final finish.
❑ 16. Place the cowl assembly on the fuselage
and mark the locations for the mounting holes. If
the engine is installed also mark the location for
the needle valve clearance hole. The access hole
for the Glow plug can be eliminated by using a
remote Glow Plug Adapter.
❑ 17. Mark the Cowl mounting hole locations on
the Fuselage. Adjust the location of the front holes
if required to clear your engine or exhaust system.
❑ 18. Glue in the 1/4” plywood Forward Cowl
Mount Blocks at the location you marked. Make
shims for the aft part of the cowling as shown in
the photo from scrap 1/32” or 1/16” plywood.
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