Cutting Cowls
 

This is the first time I have cut a cowl so I neded your advice. What Dremmel attachment is used to cut the fiberglass cowl? Any other advice would be appreciated! Thank you in Advance.

RE: Cutting Cowls
 

I will use my sanding drums. Just make sure that you have a dust mask on. Good Luck, Dave

RE: Cutting Cowls
 

I use the sanding drums also to get to finish size

RE: Cutting Cowls
 

Sanding drum, and a dust mask. Don't work in the kitchen or the living room. SWMBO will have a hissy fit.

RE: Cutting Cowls
 

For an expert job.
I tape construction paper to the fuselage (tape it back far enough so you can slip the cowl underneath without taking it off)
cut the needed holes in the construction paper fixing any mistakes as you go. Remove the engine and slide the cowl underneath, mark the holes with a fine tip marker.
Remove cowl and grind away as needed. I use a small sanding drum and a small stone as needed with my Dremmel.

RE: Cutting Cowls
 

What others posted, but would like to add a cutoff wheel works good to take out large sections without making all the dust. Finish with sanding drum.

RE: Cutting Cowls
 

Yeah, use the thin cutting wheels to make the initial openings. Use the sanding drum to finish it off, and use a slow speed. High speed will take away alot real quick.

RE: Cutting Cowls
 

I make the initial cut with a 1/16th drill. Use the side close to the chuck as a milling cutter - works just fine.

Finish off with a sanding drum.

RE: Cutting Cowls
 

dunker,

What did you mean by "Use the side close to the chuck as a milling cutter" ?

RE: Cutting Cowls
 

To cut a cowl I use the following items:

- Adhesive tape & paper ( as per Missleman )
- Drywall Side cut bit used in hand held dremel.
- Small and medium Dremel Sanding drums
- Hand/Finger drills
- Panel Line marker Pen
- Alcohol to remove the Panel Line Marker lines later.
- Dust mask.
- Shop vac running just next to where cut is being made.

Usually I position the shop vac nozzle inches from the cowl to catch the fiberglass material.

I use a hand/finger drill to drill through and start at the marks I have made with the panel line pen.

The side cut bit is used to enlarge the holes and clear out large areas.

The large sanding drum is used to finish off the larger holes, while the smaller drum for the small openings.

Work SLOOOWLY... check your work OFTEN...

I may take 2-4 hours to cut a cowl with several openings, etc. but the results are worth the time.

After the cowl is cut I usually apply thin CA on the inside of the cut areas to prevent the fiberglass from cracking and to help harden it.

RE: Cutting Cowls
 

Thank you all for your great advice!!![8D]

RE: Cutting Cowls
 

I generally use a cone shaped grinding bit. You can use just the tip for fine work or use the larger diameter at the base for removing more material.

RE: Cutting Cowls
 

About the same as John, plus I still have all my burrs and hand piece from my dental lab so I can do like Chuck too. Cut off wheels for big areas then the drum sander.