This step has me floxing in the rudder bellhorn and then hiding it in the hope that all will work out later when I cut the rudders out.

I made a foam cap for the section that becomes permanent in the rudder. Some say one ply of BID then the bellhorn then 2 plies on top. Others say 2 plies first the 1 ply. I went with two below and two above, hang the extra weight in this case. I tested for space with dry cloth and all was good. Two plies went down on top of microed bare foam making up the bellhorn pocket and then I floxed the part in place. A couple of sticks down the other end stopped it sliding around.

Next two more plies of BID on top, all done on foil as usual and finally I fitted the foam piece you see in pic 1 but permanently with micro and then gaffer tape on top for position while it cured overnight.

At the other end I fitted the two pieces you see in pic 2 with a small amount of 5 mt glue. These get removed later but I needed a top for the structural layup to come. I’ve seen others just remove the structure over the bellhorn. I may still have to but I’m hoping this method will let me leave the last inch of it all in place. We will see!

Permanent foam

Filler foam

Glass and flox