Match drill tip to HS using #40 drill, cleco as drilled.
Trim aft edge of tip to provide clearance for elevator counter balance. Plans call for a minimum of 1/8" gap between tip and counter balance. Tip was trimmed to 5/32" using permagrit tools. While observing the clearance between the tip and counter balance when moved through it's range of motion, it was noted that there was minimal clearance at the counter balance's closest approach. Considering the thicknes of the fiberglass cloth and resin that will be added over the temporary rib, and the thicknes of the final paint, I decided to provide more clearance. The tip was trimmed to provide 7/32" of clearance. This should yield no interference between the tip and counter balance when final paint is completed.
All trimming was accomplished with permagrit tools. The Permagrit tools are worth every penny of their cost!
Fabricate temporary rib from blue foam and install in tip.
Final trim and smooth of the tip was completed with the tip clecoed in place, using a masonite thickness guage.