You guys seem determined to make me lay fiberglass, with the exception of Paul, who offered to do it for me :-)  I really appreciate the offer Paul, but since I have plenty of other fiberglass work to do as well, so I'll just add this to it.

Rusty;

If you really don’t want to lay fiberglass; make up some filler using about 50/50 by volume microballoons and milled glass fibers with your epoxy.  Get it to about the consistency of peanutbutter.  After coarse sanding your ring surface, spread it on.  Best you rig some sort of inner boundary so the extending material doesn’t get more than ¼ in thick.  When it’s cured; file/sand it until it’s nice a smooth around the outside.  It’ll get hard, and it won’t easily chip.

Chances are overall you may find this about as difficult as making a foam mold and laying up glass cloth.

Or you can go for the ultimate solution and build a new cowl, like I did.  See http://members.cox.net/alg3/CustomCowl.htm; (and thanks for the inspirationJ)

Al