Top Flite TOPA0415 - Manual (Page 49)

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2. Use a bar sander with 80-grit sandpaper to true
the edges of the cowl pieces so they fit well. Clean
the plastic with alcohol, then thoroughly roughen
the inside edges of all the joints with coarse
sandpaper. Later, the inside seams will be reinforced
with fiberglass tape and epoxy. The plastic must be
scuffed for the epoxy to adhere.
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3. Securely tape the left and right cowl sides together
on the inside and the outside with masking tape. Join
the cowl front to the taped-together sides. Use CA to
glue the sides to the front, then to each other.
Note: If CA accelerator is required, apply only a small
amount just where it is required. Too much accelerator
may soften the plastic.
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4. If necessary, trim the aft edges of the cowl sides
so they are even. Tape the cowl flaps together, then
test fit them to the cowl. When a good fit is achieved,
glue the cowl flaps to the cowl, and then to each other.
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5. Make six cowl mounts using the twelve die-cut
1/8" plywood cowl block sides and six 3/8" x 5/8" x
7/8" hardwood cowl mount blocks.
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6. Glue a die-cut 1/8" plywood cowl mount base
between the supports at the bottom. Use a moto-tool to
cut an elongated hole in the center of each base. The
hole should be approximately 3/32" wide and 3/8" long.
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7. Use the template on the plans to cut the cowl
ring sections from the 5/8" x 2" x 30" balsa sheet.
Hint: Use 3M 75 Repositionable spray adhesive to
temporarily glue the templates directly onto the
balsa sheet. Cut the sections out, then peel off the
paper templates.
Note: If you do not have a table saw or a belt sander to
accurately cut out the cowl rings, keep in mind that the
ends of the cowl rings are the only edges that really
need to be cut accurately (since they determine the
locations of the cowl mounts). The outer edges will be
sanded flush with the fuse and the inner edges do not
join to anything.
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8. Test fit the cowl ring sections and the cowl
mounts to the front of the fuselage. Make adjustments
to the cowl ring sections if necessary.
Hint: Removing the elevators and rudder enables you
to stand the fuselage vertically on its tail.
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