roger.alli

Here is a tip with the toothpick method.

-Line the parts up perfectly and tape firmly in place from the inside.
-Start gluing on toothpicks from the top.
-Using medium cyno (sparingly) and kicker, glue the first tooth pick to the cowl side only. Don’t put any glue on the fuse side, or get any cyno in the gap.
-Cyno the second tooth pick to the fuse side only. Don’t glue it to the cowl.
-Work down form the top, gluing them on alternately, fuse, then cowl. Space them about 10 mm apart and work right around to the underside.
-When finished, remove the tape you used to hold the parts in place..
-Now, CAREFULLY, slide the cowl forward and off the fuse,,, with half the toothpicks still attached to each side!!
You should be able to slide it back into place with it lining up perfectly. You are now ready to apply Hysol.

The photo below is my crappy photo shop of how it will look.

I actually glue the tooth picks directly on to the surface, with no protective masking tape. It is fairly easy to remove them and refinish the surface. You will need to do some filling in this area anyway.

As Matt says, make sure you get plenty of Hysol into the seam, when you finally glue in place. It should ooze out a little bit.

Keep us posted..