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Zenith 750 Cruzer Time to tackle this fiberglass fairing! First I tried filling this space with the pink insulation and sanding it to shape. That didn't work well so I used this spray on foam insulation. I've heard of people making cowls out of this so I thought it might work here.

It does work, but it's not real easy to sand.

Zenith 750 Cruzer Sanding this is a cross between sanding and tearing. I had to be a little careful not to sand too hard and break it or pull it out.

After I sanded it I covered it with a few strips of duct tape.

Zenith 750 Cruzer Then I mixed up bondo and tried to shape it the best I could.
Zenith 750 Cruzer Once it's dry I will sand it and if needed, add a second coat of bondo.
Zenith 750 Cruzer Top fillet. I didn't mix enough to finish the other side so once this dries, I will sand it to shape, mix up more to finish the other side, and then fill in any small areas that I might need on the rest of it.

In case you're wondering, I have no idea what I'm doing. I'm learning as I go and we will see how this all works out. Who knows-I might have to peel it all off and start over. I hope not though.

Once all of this bondo work is done, it will need covered with another layer of duct tape so the fiberglass doesn't stick to it.