I sanded one edge of the rudder bottom cap for a better fit, then re-installed the rudder on the VS. The clearance between the rudder cap and the stinger is now 9/32”—this should work out ok. I used a drill bit to slip in the gap of measurement. The forward end of the cap has some interference with the side of the fuse just before the horn contacts the rudder stop. I removed a small amount of material with a sanding drum on the dremel—may have to remove a bit more, but will wait until the cap is attached to the rudder. I removed the rudder and laid out the holes on the rudder for the attachments. I plan to pop rivet and glass the bottom cap just as I did the other tips. I will leave a service loop for the tail light wire in the area of the deck under the VS which will allow the light to be removed for service.
Rudder cap--stinger clearance
This is where the cap contacts the skin at full deflection
