OK guys, thanks A TON for the help. I had to change my plan of attack...initially I was trying to construct the cowl using too few elements. I ended up using b-splines to achieve what I wanted and the results are OK. Not perfect, but good enough...I figure that anything that's not 100% done can be corrected much quicker with a piece of sandpaper than with my mouse and keyboard! This task was particularly challenging because I wanted to have the sides of the cowling transition from the fuselage side angle instead of just being flat...I've had a few flat-sided cowlings and always thought they looked horrible. I will probably forego the CNC operations just because I don't have the time to spend on modeling / translating for CNC code...it would simply take too long. I will use the model I have and cut sections through it to enable me to create templates sandwiched between layers of extruded foam for shaping. Shouldn't take too long.

Here's what I ended up with...

(click on pictures for full size)
[link=http://home.centurytel.net/rcstuff/Edge540_50cc_cowl_top.jpg][/link]

[link=http://home.centurytel.net/rcstuff/Edge540_50cc_cowl_left.jpg][/link]

[link=http://home.centurytel.net/rcstuff/Edge540_50cc_cowl_front.jpg][/link]

[link=http://home.centurytel.net/rcstuff/Edge540_50cc_cowl_fuse.jpg][/link]


Here's what can be done easily with Microstation J. This is the forward fuselage area of my project...had to leave room for a cannister muffler so it looks overly complex, but should be very easy to assemble with laser cut parts. My criteria for this project was 50cc gasser (ZDZ or DA), in-fuse cannister muffler or tuned pipe, SUPER light (shooting for 15 lbs.), quick construction, removable tail, sized to fit into the back of my Tundra with a tonneau cover closed. I think it's going to all work out nicely.

[link=http://home.centurytel.net/rcstuff/Edge540_50cc_engbox.jpg][/link]

cltom, I can't remember whether or not SE had 'smart solids'...been a long time since I used SE. The 'smart solids' was a quantum leap in 3D modeling. It makes most 'normal' tasks childs' play.

HO-229, surface modeling...YUCK! I'd probably substitute the 'Y' for another letter. I started using Microstation over ten years ago and this is the most tedious thing I've ever had to do. A little background...I used to design piping systems for large projects...locks and dams, aircraft refueling, etc. Did that and project mgmt. for years before moving on to be a software developer (business mgmt. systems). Here's a screen shot of one of my last hydraulic projects...there were eight of these rooms on the job...all different in certain aspects. The equipment is for feeding huge hydraulic cylinders that operate the gates / culvert valves on a waterway lock (among other things). Nearly impossible to design without 3D capability...especially since most of the piping was pre-fabricated to save time and money.

[link=http://home.centurytel.net/rcstuff/manifold rack and power unit.jpg][/link]
Virtual

[link=http://home.centurytel.net/rcstuff/reality.jpg][/link]
Reality (work in progress)

Designed stuff like that for YEARS and seldom had to do any surface modeling...ah, the good old days!

Thanks again,
-Tom