I fabricated a couple of wedges to bend the end tabs of the trim tab today. To get the correct angle, I clecoed the trim spar then using a piece of cardboard I scribed a line around the outside of the skin. I cut the cardboard template on the band saw compensating for the thickness of the skin. After checking that it fit properly, I transferred the shape to a piece of MDF. Then using the inside wedge I cut the outside wedge and then taped on double sided tape to all surfaces. Once the wedges were in place, I clamped the assembly to the work bench and started to bend the bottom flange first using a length of wood. The trick to get a very good edge is to wok very slowly starting at the bend line. Vans recommend clamping the parts 1/32 off the bend line since bending results in the wedges moving slightly. I didn’t do this mainly because I forgot!!, but the double sided tape I used was so strong that the tabs did not move at all. In fact, the biggest problem of this task was removing the wedges. In the end I had to cut the back end of the outside wedge in order to separate the outside wedge from the skin. The inside wedge was almost impossible to remove. The result is a very sharp bend line with about 1/16 bend radius.
