1. Sanded the other elevator tip face but it needs some more filler now. I can still use it to insure my gap with the HS tip.
2. Installed the elevators and re measured my gap using cardboard flush against the face. Trimeed off a bit from the HS and filed smooth again
3. Marked the HS tips flush with the cut in HS. See pic 1 below. I then sanded to the line while checking several times for fit as I went.
4. Made some plugs from some rigid foam and cut them out on the band saw. In pic 2 below I pressed the foam against the HS to get the cut out line and then cut it out. This piece will keep the tip open and tight againt the aluminum when I drill the rivit holes later. I also traced the open end on rigid foam and cut those out too.
5. Made a line on the HS skin 1/4 inch inbd and made marks 1.5 inches apart for 4 rivit holes top and bottom. Center punch and pilot drilled #40. Removed the tips
6.Since I forgot to glue some aluminum strips to the back side edge of the tips, I cut 2 pair of strips and clamped in place and then match drilled them.
7. Made small batch of epoxy and glued the strips in place and clecoed. This real thin stuff with out filler and I wonder if it will hold or not. It just needs to last untill the rivits are installed.
8. Next visit I will final drill the tips with backing strips to #30, Dimple the skin and machine CS the tips. I will then be able to glue the rigid foam pieces in place for the closing up process
Slowly sanding the HS tip until even gap of 1/8"
Pressing some fiber foam to the HS for cut line
Can you see the fiber foam inside? It keeps the tip pressed against the metal for drilling
