Didn't get much done today but I think I have my head wrapped around the process. I didn't read the instructions all of the way through for the gear leg fairing and this caused a little extra work on my part to get a straight gear leg fairing. I cut out the template and just proceeded to cut out the whole thing all at once only to find out later I wasn't supposed to trim the trailing edge until after the hinge was riveted in place. This was a couple of days ago. Last night while reading every single word in the plans and drawings and getting the whole understanding of it I figured I could tape the gear leg fairing's trailing edge to something straight and install the hinge. Once I had everything taped down to a piece of square stock of alumnium I clamped the hinge in place on each end about a 1-16th" further inward to ensure that the trailing edge would come together perfectly. The plans say that you can not cleko both sides at the same time. I wanted to see how straight this thing was going to be BEFORE riveting so I staggered one side of rivets about 1/4" to one side of my marks that I made on the hinge. The result was that I could see how straight it was before setting the first rivet.
Drilled, deburred and countersinked (with the hinge in place) everything. Then I reassembled it with with clekos and inserted the hinge pin. The result was not straight. The slightest amount of slop between the clekos and the parts caused a slight mis alignment resulting in an edge that was not perfectly straight. I was able to bend or manipulate the edge straightness by bending it by hand. I unclekoed everything and went back to the straight edge. While holding the trailing edge flush to the straightedge I then clekoed it back together. Now we're talking! Straight as a line. Next I removed the hinge pin and riveted both sides removing one cleko and setting one rivet at a time. Reinstalled the hinge pin and success! In the end I call it good enough. It was almost perfectly straight with a very minor tweak at the top that will be covered up with the intersection fairing. Installed it on the plane and setup a line that was parallel and straight with the plane. Using a square at the front of the fairing I decided the string would need to be 24.5" from the centerline of the plane and 21" vertical. Set up a couple of weighted boxes and taped a string around the fairing back to the boxes. Then used a small ruler and twisted the fairing to center it. Clamped it into place and made sharpie lines on the gear leg and fairing to make it easier to line up next time.
Hopefully tomorrow I'll be able to add a few reinforcement strips of fiberglass cloth to the inside of where the clamps hold the fairing to the gear legs and mix up some flox to put between the wheel pant mounting points.
The right main wheel fairing was a bit of a challenge for me as well. It was difficult for me to understand how this was to be aligned with the airflow of the plane because of the amount of positive camber the wheel has when it was not on the ground. When I reread the instructions is says that the wheel pant is to be aligned to the wheel as far as camber is concerned. When I did this it looks like the wheel pant is laying over on its side (rolling over). After thinking about it, it makes sense, when on the ground with everything attached on the plane i.e. fully loaded the wheels should be mostly vertical and when unloaded they will camber out quite a bit. I used my centerline to roughly get the wheel pant aligned with the centerline of the plane using the center of the rear pant and the most forward edge of the front wheel pant. I can't remember but I think the dimension was about 3?.125"? With this in mind I went ahead and raised the rear of the wheel pant to about 8.75" and drilled it to the U-808 mounting bracket with a #30 bit. I'll play around with it tomorrow to see if it is correct.