Desiring a really clean and detailed fit of the leg fairings, I decided to cut trial fairings from slightly thinner (0.020" vs 0.025") and cheaper big-box store aluminum sheet stock to test the fit before cutting the finals from the supplied 6061 T6 sheet stock. A little extra expense, but this provides the chance to see any trims or adjustments that need made before expending the 6061 T6 material.
This is also an application where I can do a matching layout for the holes in the fairing and the holes in the hinges on the CNC for near-perfect alignment. This allows me to drill on the CNC once with the #30 final size.
I placed and drilled the hinge holes in SNB-L06-08L, then cut it from the sheet stock. I then used short pieces of hinge scraps and rivetted attachment points for the top, bottom, and middle of the fairing trailing edge. I drew a centerline for the leading edge fold, and clamped a 1 1/4" dowel over the line to a bench surface, then hand bent/formed the leading edge.I hinge-pinned the trailing edge attachment points and confirmed shape.
Cutting and pre-drilling leg fairing assembly SNB-L06-08L
Attached three short-pin hinges forming around a 1 1/4" dowel.
Testing folded form to a simulated leg for snugness of fit.
