New parts from Van's arrived pretty quickly so I was back at it. First order was to put the new HS810 and HS814 on the front spar and match drill all of the holes. Next step was to trim down the ends of these two pieces. This is the step I screwed up last time so I was determined not to screw them up again. Instead of trimming them on a saw or with a cutting tool, I elected to take them to my belt sander and grind them down to size. This may have taken more time between using the belt sander and polish wheel but in the end I got the shape I needed with a lot less headaches along the way. In the end, you really only need to trim them down a very small bit so that the edges do not protrude up above the flanges of the spar. One of the pictures below shows one of the parts, either HS810 or HS814, as it sat initially against the spar web and you can see how much material (or more precisely how little) needed to be removed to make them fit. With that complete it was time to take these parts to the vise and bend them to match the sweep of the front HS spar, 6 degrees aft. I had done a lot of reading on this step and felt like I was prepared. With the parts in the vise, a piece of 2x4 servicing as a form to keep from pinching the aluminum, a few more 2x4 bits clamped together to hold the ends, each end was bent over slowly and checked with a digital angle measure. If you're paying attention you can spot what I did wrong here pretty easily. The aluminum is soft and bends very easily so all the kit with the 2x4's and vise clamp is honestly not required. One important part is for the bend line to be at a specific distance from the center of the part. That's the only really challenging bit. In the end, once I figured out that I had actually bent the parts in the wrong direction first (DOH, did you catch that?) I was able to easily bend them back in the correct direction and get the angles just right. I ended up just holding the parts down against my work bench edge and using the edge of the table as the form to bend them at the correct location. This actually worked as well if not better than the whole get up with the vise clamp. Again sometimes simpler is better.