Beautiful day outside and wanted to get some epoxy work done. Holding off on the left tip, I went ahead and started on the right tip. Low and behold the right tip had a nice scribe line of where to cut. After measuring it comfirmed that it would leave the 1/16” to 1/8” gap in the joggle. Cut again with a pull saw and sanded with the permagrit bar, checking the fit as I went.
Finally got the right tip where I was happy and clamped and taped it in place. Double checked the alignment and drilled the holes. Much better alignment all around. They're a couple holes with minimal edge distance but I plan to install an aluminum backer plate and will add some flox to the edges.
Did an initial sanding of the tip seams and the joggle then proceeded to fill the joggle gap with flox per chapter 5. I wrapped the skins in electrical tap and clecos the tip in place. Then mixed up some flox and used a ziplock bag to dispense directly in the gap. Smoothed it out with a hotel key card and will let it cure.
1/1: Happy new year! The great weather continues and this morning I sanded down the flox from yesterday. Transition looks good; will look better after micro. I'm out of epoxy though so looking for something else to work on.
Went ahead and cut the lense for the tip light on the left side. Separated the big single lense into left and right and then roughly marked the outline of the lense within about 1/2” of final. Cut that with snips. Fit it a little better now and marked with about 1/8” of final and cut with some nice curved lexan scissors I had from my RC car days. Continued cutting it closer to the line and remarking with masking tape. Got it close enough and then sanded the edge smooth 80-100-160-220-400 wet. I intentionally left a small gap that I will micro similar to the tip onto the end.
Still looking for things to do, I marked the line to trim the trailing edge of the right tip. Just marked it with a straight edge clamped to the aileron and then cut it with the pull saw. Finished it with permagrit bar. Came out good.
1/2: Out of epoxy so worked on the reinforcement strips for the nut plates. I had a trashed aileron skin that I held on to and it is just the right length to cut strips from. So marked off four 5/8" wide strips and cut them on the band saw. Sanded and deburred the edges and primed one side. Meant to do the other tip lense today but ran out of time.