The gap under the lower portion of the horizontal stabilizer is fitted with aluminum gap fairings and a rubber seal. I deburred these, match-drilled the aft holes, and cut the rubber seals to length.
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221228_2202225183389822532371734283.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2022/12/pxl_20221228_2202330116833468673195399273.jpg)
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I didn’t have a 3/32″ strap duplicator so I had to wait for that to arrive before starting on drilling the holes in the empennage intersection fairing. The plans have you use a light shining through from the inside but the newer gel-coated fairings aren’t very transparent and there is no easy way to maneuver a light with the fairing in place.
I established the general position by taping it into place and shaping the fairing with a heat gun. I found that setting the front position, then pulling back to the aft with slight downward pressure allowed me to get a reasonably close fit along all of the skin surfaces.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_0404033238364713710631844693.jpg)
I did a bit more tweaking with the heat gun around the horizontal stabilizer and I match-drilled select holes from the forward to the aft. Others have indicated that it is easier to get a clean fit with fewer screws so I selected only the holes where I felt I needed a closer fit.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_0404185012196395539243073156.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_040420899835049865522377497.jpg)
After getting the holes drilled (and doing more tweaking) I marked the edges for trimming. I trimmed with a Dremel and smoothed the edges with a file and sandpaper.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230108_2226354144888400548864111462.jpg)
After a few more tweaks with the heat gun, I taped off the aluminum with a layer of packing tape, mixed up some epoxy and cabosil, and buttered the outer flange of the fairing with it.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230109_204505464518571696123419123.jpg)
I then clecoed the fairing into place, squeezed out the extra epoxy, and left a small bead on the outside edge.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230109_2045091001890042509064819222.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230109_2045113625081826943328475950.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230109_2045220558689029048160206266.jpg)
Once it cured I separated the fairing from the packing tape and lightly rounded the edge. This gave me a really clean fit against the skin around the entire edge.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230123_0209565268217588601060186227.jpg)
I then removed the vertical stabilizer and drilled the holes for nutplates. These were dimpled and riveted into place.
![](https://airplane.allanglen.com/wp-content/uploads/2023/01/pxl_20230123_0303325697156979809832435231.jpg)
I then countersunk and tapped the longeron screw holes and dimpled the gap covers.
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0330010343227902093982788854.jpg)
After priming the inside of the gap covers, and countersinking the fairing, I installed the fairing temporarily with the screws.
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0330050452932304755985608622.jpg)
The fairing fits really well and sits tight against the skin.
I’ll have surface finishing to do, but otherwise, this fairing is pretty much done.
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0330408215441426249180333597.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_033046551444397643459148946.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0337415127513495541191035959.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0337383487173711682476721346.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/02/pxl_20230205_0337344736847914639244004827.jpg)