First fit of lower cowling
Here is another photo showing the lower cowl.
And finally a picture showing the "lip" of the front lower cowl.
Armed with these photos, we set out building a cardboard template.
This gave us a rough outline to trace onto a piece of 3003 aluminum.
I wanted to leave a two inch lip below the firewall. Hopefully, this will allow enough air to go through the radiator and out the bottom to keep the engine cool. I guessed at this dimension after looking at the old photographs.
Now, it was time to cut metal.
The front lip was curved using a manual shrinking die.
Cowl on...cowl off...make an adjustment...cowl on...cowl off.....etc.
Here is the front lip. I left the protective plastic on the metal. This will come off later and the shrink marks will be sanded out.
Here is the rough fit of the lower cowl. There is much more finish work to be done.
More soon. Enjoy!