Great Planes Corsair 40 Kit - GPMA0177 - Manual (Page 31)

D 5. Glue two 1/4" x 1/4" x 4" triangle sticks from 1/4" x
1/4" x 12" tri-stock (F10) to both sides of the belly fairing
sides, flush with the top of the sides. Trim the triangle sticks
to allow the wing bolts to be removed.
D 6. Remove the wing from the fuse and remove the wing
bolts. Cut three 4-1/4" long pieces of 1/16" x 3" sheeting.
Edge glue the three pieces together. Place a mark 7"
forward from the belly fairing end. Set the sheeting on the
aft belly fairing sides with'the forward edge flush with the
line. Sand the forward end to blend into the wing. Glue the
sheeting to the belly fairing sides, end and the wing. Trim
and sand the sheeting flush with the aft belly fairing end.
D 7. Using a 1/4" drill bit, insert the drill bit through the wing
bolt holes from the top of the wing and drill through the
belly fairing sheeting. Enlarge the holes in the sheeting to
allow the head of the wing bolt to seat against the
wing plate.
D 1. Trim the cowl ring (COWL028) and the cowl flap
(COWL029) with a scissors using the embossed cut lines
for reference. Use medium CA to glue the lip on the cowl
flap inside the cowl ring. Sand the joint on the inside with
220-grit sandpaper and clean it with rubbing alcohol. Use
thin CA or 30-minute epoxy to glue the 1" fiberglass strip
over the joint inside the cowl.
D 2. On the cowl ring, place marks 1/4" forward from the aft
edge at the 1 o'clock, 5 o'clock, 7 o'clock and 11 o'clock
positions, in the larger cowl flap area, as shown on the
plans. Use a 3/32" drill bit to drill a hole through the cowl at
each mark. Place a mark in the center of each 1/2" x 1/2" x
1/2" hardwood cowl block (F13) and drill a 1/32" hole
through each block at the mark.
D 3. Sand the drilled end of the cowl blocks to match the
curvature of the cowl.
D 8. Reinstall the wing on the fuse and sand the aft belly
fairing to blend with the fuse and the wing. Remove the
wing and clean up the LE and TE of the belly fairing.
D 4. Cut four 5/8" square cowl mount pads (F24) from the
1/32" x 5/8" x 3-1/2" birch ply sheet. Sand the area around
the screw holes in the cowl. Glue the cowl mount pads to
the cowl with 6-minute epoxy. After the epoxy cures, drill
through the pads with a 3/32" drill bit.
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