Since my experience with using plaster was so rewarding with the stabilizer tips, I decided to make my own rudder cable fairings out of fiberglass using a similar technique. I perpared a mold out of wood and clay to pour the plaster into. I then cleaned up the mold with sand paper. I decided where I wanted the rivet holes in the end piece. I drilled and countersunk holes in a piece of aluminum at those locations. I used this piece to glue rivets onto the surface of the plaster to form the dimples in the fairings. The fiberglass would be too thin to countersink holes in it. Although its not visible here, I actually #65 holes through the centers of the rivets and into the plaster so that the rivets wouldn't fall off when the fiberglass was pulled from the mold. I then glued a wire through the rivet into the plaster using epoxy. I applied bees wax to the surface as a parting compound. I layed up two fairings using this mold.
