I did all this yesterday and a bit the day before and spent today lining up the right winglet and remeasuring things. I also made improvements to my aluminium measuring system. That means sharpening a few sticks… to very exact lengths.

No pics of all that but here are a few of making the wing cutout.

Once the trial setup is done I drew a line. I used the dremel to cut the top of the wing just back from the line. Then it was carefully cutting the foam away with the dremel and then the bottom skin. All the while being really careful around the antenna and rudder conduit and using a square to keep things even..

I bet someone else would do a nice job in 10 minutes with a coping saw. I took many hours and used permatgrit files to creep up on my cut line. Yeah …no nicks on the vital bits. That was a 12 hour day. I might be a bit quicker when I do the other wing cutout… OK…probably not. I am happy with the result.

Winglet bottom curve

Wing cutout

Wing cutout ready