I decided I could not live with the amount of mismatch shown on the previous page so I ripped out the plugged and drilled off the pulled rivets and removed the tip. Then I sanded down both the aluminum VS and the tip to remove excess fiberglass.
I played around with the tip and discovered with just a little manual manipulation I could make the tip flush on both sides of the VS. You can't trust just putting the tip on up to the indention on the mold. You need to staighten the tip, regardless of where the indention falls. I'm going to fill that seam in later anyway with fiberglass mud.
I close up the previous holes in the tip with some fiberglass and cloth.
