In order to get the correct angle and travel of 5.5" for the rudder swing I had to add an extension to the bottom of the rudder that was angled. I hot glued a larger than needed foam block to the bottom of the rudder then carved and sanded it down to the correct angle to allow for 5.5" of rudder travel. In doing this it was necessary to take of some material at the conduit location into the trailing edge of the wing. I then laid up using the same layup schedule of the winglet (2 plys UNI and 1 Ply BID) on the side of the foam. Once this is dry I will top it off with flox corners and 3 plys BID on the top. once that is dry I will hot glue the internal bell horn in place and make one last check for rudder sweep angle using the rudder cable. If everything is ok I will drill a few holes thru the BID directly under the bell horn holes see pic #2 and fill these with flox and place FLOX all around embedded bell horn and top it off with 1 PLY BID.
