Originally Posted by Janekom
With regards to the rubber, just make a small recess in the fairing where the rubber is.
I tried notching it but the portion where the fairing contacts the fuse pretty well follows the channel all the way down to about 1" from the aft edge. So I'd have to slice pretty much the whole side and then lay up glass over it to make it look decent.
I can certainly do that, but it would take a fair amount of time. And for the heck of it, I dragged the Van's ones I'd bought out of the box of old useless things, I found they fit a bit better. Of course, those need a lot of glass work too, but the difference is the "joggle" over the uneven area between the wing gap fairing and the bottom of the fuselage (at least on my plane; I might've built it wrong).
... and probably will require less work.
The lower intersection fairings, however, are no contest. I just had to move one nutplate connecting the front and back wheel pant (you can see the one that had to be moved in the following picture, it would get covered when I smoothed out some slurry), and shave off a little clearance for the inboard lower screw that holds the back half of the wheel pant in place.
I was going to go with the "screw it on and be done with it" method, but now I'm leaning toward the "screw it on, slurry the edge, and slice it on the seam" style.
I'm not going to trim the aft edge at all because I rather like the look.
By the way, in Bob's images above, it looks like he split the fairings and then bonded. Is that the preferred way? Or would it be better to bond the fairings and then split them?