I glued foam between the ends of the unfinished fairings and the 3/4" spruce ends I glued between the fuselage and wing at the front of the main spar. The foam was glued in place with fiberglass resin by Bondo, nothing special, mixed with micro balloons into a near paste. I find a increase of 50% catalyst works better when making a paste this way. The foam in this case is 1/4" thick LAST-A-FOAM from Aircraft Spruce. Next I laser cut two1/16" thick by 1/2" wide end strips complete with screw holes for #6 sheet metal screws. The strips were comepletely covered with Johnson Paste Wax and buffed with a paper towel. This wax WILL NOT allow the fiberglass resin to stick to it. Some others I have tried do not always work! The strips were then clamped into place. I drilled pilot holes in the spruce centered on my laser-cut holes and screwd the strips in place. The strips are only here to allow the production of a perfectly straight edge with the fiberglass. They will be removed when the edge is complete. I used my CAD system to design 4 different width fiberglass pieces to stack up and fill the area between the strips and the end of the existing fairing on the aircraft. These were laser-cut gicving me edges that would not fray. I beveled the edge of the existing fairing nd then cleaned the area up. Finally I glassed the 4 layers in starting from the narrowest one and adding the progressively wider pieces to create the edge I wanted and a scraf joint to the existing fairing. All this work yeilds a 1/16" thick ledge for the rear of the fiberglass fairings I plane to make for the front of the wings.
