Here is how I made the cowling for my Magic.

You can use the same steps for just about any .40 size cowling.


The pictures above show you how I made the template for the plug. Take the time to make good templates. The end result will be worth the extra time you spend on them.



I made the plug from 3/4 plywood.



After the pieces were epoxied together. I mark the plug where it needed to be sanded. Then I used a 6" belt sander and sanded the plug to the marks. Check the fit and be sure it is right.

Then cut the bottom out of a coke bottle. Push the plug inside as shown. Then heat the bottle. The bottle will draw up around the plug. The more you heat it the smoother it will get. Then cut the plastic flush with the back of the plug. This will allow you to remove the plug from the cowling by pulling on the top and holding the plug from the inside. (I use a dowel I put in two holes I drilled on the inside of the plug.)



Just don't get it to hot in one place. The trick is to keep the heat moving. Here is a look at what happens when you get the plastic to hot. (image on the left)
The image on the right shows you that when your making the plug you will waste a few cowlings getting the right fit. Once I have the right fit. I mark the cut-out on the plug. This will allow you to get a perfect fit.



Now your ready to make the finished cowling.



To cut the top off I use a piece of wire I heat red hot.



This will keep the cowl from cracking later.



Then I sand the front edge so the lip is 1/4" wide.



Then I fit it to the model. (left)
I then epoxy balsa to the firewall and drill the mounting holes for the screws. (center / right)



Then I mounted the cowling and checked the fit.



"WAIT Here is a Tip I use on all of my models."

You are not done yet!
There is one more step.


Remember the mounting holes for the cowling?
Well, That small screw is going into wood and in many
cases it will at some point get fuel on it and at some
point you will loose the cowling screws.
So, to keep them in place but have them removable.
Here is what I do. Drill out the hole with a #27 drill.



Then CA a short piece of plastic antenna tube in the hole.



Then add a little epoxy as a backup to the CA glue. (I let the tubes run long on the inside so the epoxy has more to bond to.)
Since I started doing this I have not lost a cowling screw.


OK... NOW, Back to the Magic project.



Before painting I sanded the cowling really good.



Here is a look at the cowling after painting.



Here are a few pictures of the finished cowling mounted on my Magic.


No time to make your own Magic Cowling?
You can get them ready to trim, mount and paint.

The cowlings are $3.00 each plus shipping Order here


Click Here for more information on how to mount the cowling.


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