I use standard cheap styrofoam. Tack glue a chunk on the planes firewall and sand to shape. Paint on a very thined coat of water and elmers white glue. Fill in the dents with light weight spackling and sand again. Paint on another coat of water/white glue. Then glass over the plug using thined epoxy or finish reson. I suggest using a heavier glass cloth 2 to 6 oz at about 3 layers. You will end up sanding one layer off. Sanding goes pretty fast if you use an aluminum sanding bar with aluminum oxide stick on sand paper, about 80 grit, for the rough sanding. Make sure the overlap past the firewall onto the fuse sides isnt too long, you have to break if off at some point. When done, break off from the firewall. Pour a little gasoline onto the styrofoam and watch it dissolve. Scrape out the crap and clean it with soap and water. Sometimes its easier to do the finish cleaning on the inside when its dried out and use a dremil with a wire crown bit and wire wheel bit. And thats all there is to it. This is a male mould process that does the cloth on the outside. It gives a decent finish dependent on sanding. Takes about a weekend to make a cowl. I wrote an article for the clubs newsletter last year about this. Contact me PM if interest in a copy.

Edwin