I started grinding away at the inside of the lower cowling to smooth the edges between the old cowling and my new piece of cowling.

I applied a layer of resin-flox mixture to the seems and sanded it down. After that, I applied a layer of resin-mico balloons and sanded it down. The blue filler you see here is a Poly-Fiber product. It has some really nice self-leveling properties and works very well at filling minor imperfections.

I've sanded the first layer of Superfil. I've also added a few layers of glass to reinforce and smooth out some transitions around the smiley intake. The lose pieces near the smiley intake are peel ply fabric. I try to use peel ply whenever I can because it minimizes the amount of sanding I have to do later.

The blue filler does a pretty good job of smoothing transitions. I always tell people to keep filling and sanding and filling and sanding until you think there's no way a seem will show. Once you prime, you'll probably see that you should have done more... but at least you'll only have to do one or two more steps of filling and sanding!

In looking through all my cowling pages, I realize I never really showed my new carb intake and how it will line up with the new smiley. I took this picture as I was developing the concept. The forward piece is just taped in place, but it eventually became part of the smiley intake and carb air bypass door setup. The original Air Maiz filter/intake system was way too big to fit in my new streamlined cowling design.

Back on Page 16, I mentioned that there were a few pictures that I couldn't find... Well, I found them so I'm just going to insert them here.

I had a local exhaust shop make me a small heat-exchanger tube. Van's sells a similar unit, but for exhaust systems with larger diameter pipe. I need to check with some Van's folks as to how then attach these pieces to the exhaust system, but I assume they use a hose clamp and cut small slits on either side of the mouth as it goes around the exhaust stack.

The idea is that I'll attach a piece of scat tubing from this tube to the carb intake box. When the intake box closes to ram air, the engine will suck warm air through the SCAT tube which will suck air over the exhaust pipe. Not ideal, but given that EGTs are usually over 1200 degrees, I'm betting I'll be able to get at least a little rise in my carb intake temps.