Here goes!
This is my plan with the empennage tips:
Remove all the polyester gelcoat from all parts
(I've seen many not do this)
Clean
(acetone?)
Use aluminum rivet washers for reinforcement and glue them with E6000.
Scuff the aluminum skin approximately 1.5 inches inboard with 80 grit.
Make balsa ribs for HS and VS. Use Van's method to reinforce them. Fill recess with micro slurry.
Butter the fiberglass joggle with micro or 410 and then rivet with CS-4 blind rivets.
Scrape "oozing" material away.
Use Dan H's method to "hide the lead" on the elevators.
http://www.vansairforce.com/community/showthread.php?t=57851
Either use tape or devise strips from cloth for the transition between aluminum and fiberglass.
(Don't know if this should be one continuous strip and where to begin/end. I ordered P/N: 01-6610 from ACS...seems thick)
http://www.aircraftspruce.com/search/search.php?SRCHTXT=01-06610
Use thick plastic sheeting to sandwich strips and epoxy to wet them. Use squegee to remove excess and air bubbles.
Apply epoxy to seam of tip and skin.
Remove top of plastic sheeting and place strips on joint. Remove remaining plastic sheeting after air bubbles are removed.
Make sure strip is seated properly, then apply Peal Ply.
Let dry.
Remove peal ply.
Fair tip to skin with 410, sand, fair, sand, etc. until good.
Clean, then use Superfill to attack any pinholes.
Contact painter I plan to use. Find out the paint system they use and apply the correct primer.
Does all this sound correct?
Any suggestions otherwise before I proceed?
Everyone has been very helpful.
Thanks again.