This looked a bit fiddly and it didn’t disappoint. I found I hadn’t made the LWA6 insert (pic 1) so cut a couple late last night. They will have to be alodined before installation.

Today after a lot of marking out and thinking I made the recess as in pic one and adjusted the metal edge to suit the curve in the sheer web area.

Next as in pic two I had a couple of access areas to carve out of the blue foam. This took a while on the first one as there is a glue join going right through it. The other side was much quicker. I did these very carefully and even had a socket wrench to ensure the cutouts will be deep enough. Its pretty much plans size where the hardpoints go, which it has to be, and a fraction bigger elsewhere, .2″ at the most.

Then I cleaned up and used quite thick micro to line the inserts followed by two plie of BID done on foil. I used my gloved finger to sort the micro. I did make a pleat cut at the bottom of the BID square and folded it over so the piece would fit in.

It looks OK. Once cured I can trim it and then cut for the metal pieces. Amazing to think this is going to hold the wing on. Crazy.

Inboard insert

Outboard access cutouts

Two ply of BID each