The majority of the the stabilizer fairing construction is described here. If you have long enough aluminum stock, you could make these one piece but that would be considerably harder than two-piece. I drilled #40 holes every 3-1/8 inches, using the previously mentioined jig, and then tapped them to 6-32. It was necessary to use a 45 deg pneumatic drill for many of the holes. The best way I found to put it together was to make the upper surface was to get the straight portion drilled and then bend the aluminum around. The straight under surface is relatively straight forward. The aft end of the upper and lower surfaces are bent to conform with the tubing. It is also necessary to notch the inner surface to account for the front and afti tubing fairings. Finally, I found it best to drill the hole for where the front stabilizer bolts run into the fairing, rather than notch it.
