Filled "slot" at aft end of RH Tip (reference earlier recent posts) with epoxy mixed with microlight. note: previously reinforced inside with cloth/resin anticipating this gap once I cut off 1/4". I'm sure glad I noticed this on RH Tip, since LH Tip was A-OK at aft end. Finally, it was time to cut the polycarbonate Lens...which ended up being less traumatic than anticipated. To prepare, I used a portable electric heater to warm the part up (warm to the touch), since garage was only 63 deg. Using a dremel with fiber cut off wheel worked well - essentially the material "melts" - there was minimal dust to cut apart the LH/RH thermoformed shell. I kept the heater on as I trimmed the LH Lens. Per Van's Step 3, I trimmed front and outbound ends to establish initial fit, then marked and trimmed off perimeter. Using a small drum sander in dremel allowed me to quickly trim to a line. I'll hand sand tomorrow to get final fit...then Repeat for RH Lens. Note: Scrap pieces allowed me to practice with plastic drills and countersink (Aircraft Tool Supply Zero Flute Countersink 3/32-1/4"). Reference VAF for excellent tips on cutting polycarbonate.
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| filled "slot" aft end RH Tip - sure glad I reinforced inside 1st |