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Posted for "Skip Slater" <skipslater@earthlink.net>:
Steve,
On my ES, I used a Legacy lower cowl as a mold to make my exhaust blisters. Luckily for me, there was a Legacy builder in the same shop where I built my plane who let me use his cowl.
I put release tape over the Legacy blisters, did a 3 BID layup on them, trimmed them, clecoed them in position on my cowl until I was happy with their location, then glassed them on with an extra BID inside and out. They're lower profile than the IV blisters, blended in very nicely on the ES cowl and, in my view, create minimal additional drag considering the increased amount of air they'll allow through the cowl.
The extensions aft of the firewall not only look sleek, but they allow me to stand the cowl on end when it's off the plane without it's tipping over. (A minor, but handy feature.)
Skip Slater
N540ES
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