Brief Description: Bonded a Leg Stiffener to the Right Leg
Bonded a Leg Stiffener to the Right Leg using Light Weight Bondo Filler. The Bondo was allowed to set for about 45 minutes then I sanded it to remove the excess. When I put the fairing on over the stiffener, it was obvious that I would have to remove material from the stiffener. The Fairing fit way too tight to the stiffener, making it impossible to insert the hinge pin. Besides the stiffener being too fat, it became apparent that during the process of riveting the hinge to the fairing, the inboard end of the fairing had migrated slightly towards the middle of the fairing. This made the inboard end of the fairing particularly wide and unable to accept the hinge pin. The fix would require shortening of the inboard cord and removal of material from the top and bottom surfaces of the stiffener before the fairing would be able to fit.
The fairing was sanded and the excess bondo was removed and feathered. After a good bit of effort, the fairing fit the stiffener. The fit was tight and there isn't very much freedom of the fairing for adjustments. I'll check the fairing alignment before proceding further with stiffener alterations.