Lots more shaping takes time. Pic 1 shows how I have to carefully remove micro with a dental bit in my cordless dremel before more shaping. Files and sandpaper seem to go straight into the foam and leave anything hard alone so the best strategy is to get the hard stuff out first.
I still don't have a final word on the shape of the new lights from Aveo that replace the ones I'd like to use. I just hope the new footprint is close to the old lights. If not I may swap a new set with the ones I have installed on my flying plane. I like the profile shape of the old ones and I've set this up so it can inlay into the wing and be even less proud of the winglet tip.
Pic 3 shows I've gone for a flat bottom with about a half inch radius ending in an almost glass to glass trailing edge. It may be slightly round and I'll dremel it out and fill with flox later... thats the plan.
Overall I finished this up and did a 12 hour day including the layup on the next entry. I'm still being conservative with my estimated workshop times. This build is taking a while yet each step in now in the past and another completed process. I don't think about the past too much.
