Tonight I cut a hole in the left flap fairing so that it would fit around the step. I started by cutting a hole in a manila file folder which fit around the step where it meets the fuselage. Then, I located the holes which attach the flap fairing to the fuselage and punched some clecoes through when the hole fit around the step well. Then, I transferred the template to the flap fairing and located the position of the hole using the cleco holes I punched in the template. Once I traced the hole position in the flap fairing, I drilled some large holes with the step drill and finished it off with a grinder in the dremel tool. As usual, it took some grinding and fitting before it all fit well. Then, I had to drill some more cleco holes through the step weldment where the original flap fairing holes were located. A little massaging and it all looks pretty good. Once I finish priming, and once I get a riveting partner in the shop, I can finally rivet the flap fairings onto the fuselage.
The manila folder template on top and the cut out flap fairing on the bottom
