Hi Brian
I just completed installing my cowl access covers. I used an American Quarter
for
the radius of my corners which seems about the same as you have laid out. I
used an Xacto mini vertical saw to cut out the radius and a mini model back saw
to cut out the straights. Very thin cuts. Anyway if I were to do it again would
use minimum of a UShalf dollar or better a silver dollar radius. It may save
you some tedious fill after you fail to follow line as close as you anticipated.
That said "when" you need some fill, JB KWIK Weld is pretty strong, sands good
enough and if you catch it after about 10 minutes with a sharp knife, it slices
like leather. I needed to fill the edges on my covers and the JB KWIK worked
great. I added some 3/4 oz Model cloth over the rivets and filled edges of cover
to support better.
Ron P.
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