Reviving an old thread. I'm planning to make my bottom rudder fairing removable as well (#6 screws), to give more convenient access to the tail light wiring. I found the fit of the fiberglass part against the rudder skin is not very precise. In particular:
1. The fiberglass is thicker than the rudder skin, leaving a pronounced edge along the surface. If I were permanently attaching, I might choose to fill that edge with some epoxy and file it smooth. Any good approaches for making this edge nice while keeping the bottom removable?
2. The fit is particularly bad against the forward R-710 "horn brace" where there are no fasteners called out. There is at least a 1/16" gap between the metal and the fiberglass part. Suggestions on how to solve?
RV-7A (N12VD): Everything done that can be done at home. Waiting for hangar to finish up.