bunch of hours strung out over 3 weeks. I had to go to Missouri to help dad with some financial stuff and ended up getting covid while I was there. Resulted in me being trapped at the lake house for an extra week. Covid is a bummer, but there are worse places to be trapped :)

Anyway, I've been chugging along on the baffle/cowl setup as time allows, and I think I've just about got this thing licked. I filled in behind the cowl inlets per the rv14 plans, then did the uppers to match. Lot's of sanding/grinding to get the shape right.

I think the baffle rubbers will fit correctly now, but when all everything is in its final position, the l/h outboard corner has a bit of an underbite due to that area not being molded 100% correctly on the upper cowl. I've tried a ton of wiggling and finessing to correct this and considered building up the back side of the lower corner in order to give enough meat there to sand it down to match.

Ultimately, I determined that the issue was due to the upper outboard corner trailing aft about 1/16" between the spinner ring and the outboard edge. The only "correct" way to fix this that I can see is to build that area up.

I started by taping off and then sanding off the gel-coat in that area, then waxed, taped etc and installed the cowl halves in their final position.

I then applied a layer of epoxy/flox with peel ply, waited for it to get tacky, then followed up with a slathered on layer of epoxy/micro. after it was solid but not hard, I made sure I could remove the aluminum spacer pictured below. I also sliced off some high spots with a x-acto knife.

Once this is hard I've got a ton of shaping/sanding ahead of me. I hope I'm talented enough to get the shape right on the first try, because I really don't want to go through this process again.