I want to build Cowl for my Pheaton II, since the one that Balsa USA sells for this model is horrible.

I have never done it before. I heard that a bottle of coke or any other bottle that fits would do. However, do I just make it fit and paint it? or do I have to reinforce it with something else?
Wouldn't the heat from the engine melt the plastic bottle?

I would apreciate any suggestions on this.

Thank you,

Paul

Paul,

Do a search on RCU for cowl suggestions. It can be built from several materials(balsa, foam, etc.). I've been trying to decide on a method for my Venture 60 and am still debating with myself.

Good luck,
Jason

I feel sure I am not the first to do this.... I just have not seen one in my limited amount of time in this hobby. (2 years). This may be an alternative for someone wanting a cowl for their plane. This cowl is on a 4* 120 I am building. A Saito 150 is mounted sideways on a GP adjustable mount. The "top part of the cowl is a
carved block of balsa. I have a 4-40 threaded rod and nyloc nuts connecting the cheeks for support near the top front. (this rod is hidden by the top piece that "curves" over the top of it). I really didn't do this to save money..... I just was not having any luck finding a fiberglass cowl that would fit. (I did have a request for ideas on the forums, and found one.... but it had to be altered on the corners and I was afraid of working glass)
PS. I did not use the "tripler ply" on the removeable cheek).... lownslo...

I've heard of this and seen it work, but today's bottles do not have the solid plastic base of yesteryear. You can use a 2-liter base as long as you have good air flow for engine cooling and obviously plastic cooling. They will melt away if to close to the engine, and what a mess that turns out to be. OR you could use a 2-liter bottle as a form and wrap with 1/32 to 1/16 plywood and use fiberglass for the front of the cowling.

If you decide to go this route, get a fresh bottle of soda/pop, as they have high pressure, soak the plywood to give it some flex, usually place wood in a plastic ziplock bag with enough water to soak into wood. Let the wood soak for about 1-2 hours or until you can flex it. Take the wood out, let dry slightly, just until it turns a light/dryer color and bend around the 2-liter form (don't forget to wrap the bottle with Saran Warp, as this keeps the epoxy and CA from sitckin to the bottle), expoxy, and hold with rubber bands and/or tape...once you THINK it's ready to remove, shoot with some thin CA, let rest and carefully remove. Again, let set for 1-2 hours, and your ready to go. Maybe...This can be a very tedious and time consuming skill project, but well worth it.

P.S. I gave you the Readers Digest Condenced version of instructions. Please think thru, and plan ahead.

Fiberglass specialties has both styles of cowl for the BUSA Phaeton 90, cheeks and no cheeks.
http://www.fiberglassspecialtiesinc.com/CATALOG.HTM

If you really want to make one, a plug can be made out of styrofoam. Then glass over it. But just buying one would be a lot simpler.
Edwin