Fiberglass Tips 

I figured I'd add a little info here pertaining to the way I finished off my fiberglass tips. These tips are different from the first batch of -7 tips in that they incorporate a new style counter-weight.  Lot's of fun here... Note that this process assumes that the elevators are already adjusted and the skin on the HS has been appropriately trimmed. The basic process is to do a general fit of both tips, fit and finish the elevator tips, then fit and finish the horizontal stab tips. This is the same process I used on the rudder and vertical stab. There's several ways to do this but I found this works for me. Because you end up filling with epoxy filler, then waiting for cure, then sand, fill, sand, fill, the process is pretty slow. I get about an hour of work, then wait for the cure. Since I'm also waiting on the wing kit at this time, I have the time to do this and it beats rushing through this step when the aircraft is almost ready to fly.

	Step 1	Slide the new tips into place. The HS tip is now a bit long since we trimmed off about 3/4" of the skin. You will want to just trim enough to allow the elevator to swing to the trail position so leave a little for final adjustment.
	Step 2	The elevator tip is roughly positioned. Due to the shape of the lead counter-weight (and you don't want to trim too much off of the lead), the tip fiberglass is now a little too wide to match the outter mold line of the counter-balance arm skin.
	Step 3	Solution to the tip width is to carefully sand the interior of the it so it will lay flush with the counter-balance skin.
	Step 4	Here's the HS tip being spread a bit. I cut a piece of glass-coated foam to shape and used to carefully spread the HS tip. Then use a heat gun to relieve stress on the tip. Over time, and a with a little heat, you can reshape some of these things. The foam is only temporary so it comes out when the aft plug is added.
	Step 5	Now we have the tips roughly the right shape so I epoxied 1/2" strips of .020 AL to the tips to serve as reinforcement for blind rivets.
	Step 6	Now the fun part. Blind rivet the elevator tip to the elevator. Some minor sanding and adjustment may be needed to fit into the trailing edge. After fitting, I cautiously apply some heat with a heat gun to basically set the fiberglass, than rivet.
	Step 7	This is the front of the tip after riveting. Note the overhang on the counterweight. This will be fixed with patience and good 'ol West System epoxy and fairing filler.
	Step 8	Goop on some West System epoxy fairing filler. I've been using the West System 105 Epoxy and the 205 Hardener. This is a quicker setting hardener and works well when the temps start going down. Then mix in the 410 Microlight Fairing Filler. This is a lightweight fairing filler that mixes to the consistency of peanut butter and sands very well. Good Stuff!
	Step 9	Sand as required. I'm using 100 grit for starters, then going with 220 and finishing with 400. Makes for a smooth finish.
	Step 10	After the basic shape was done, I added a couple layers of light glass cloth for a little strength to tie the sides together.
	Step 11	Now sand as necessary again and fill, sand, fill, sand until you're done.
	Step 12	Back to the Horizontal Stab tips. I cut two fillers out of glassed 1/4" foam. A scrap can be seen in the foreground. Cut to fit, then epoxy to the interior of the HS tips. I added a couple light layers of glass on the interior.
	Step 13	Sand to fit as necessary. This can take some time and patience again.
	Step 14	When the fit is adequate, do the blind riveting thing again.
	Step 15	Use the trusty West System again to fill the join lines and the blind rivets, then take a finger and fill the small gap on the aft side.
	Step 16	Tips have been primed with PPG DP epoxy primer and are ready for storage. I'm going to keep the interior of the counter-balance open as well as the interior of the HS. I figure this will help with drainage and inspections.
	Step 17	After priming, there's some minor filling yet to be done but that will get completed during finish paint.
	Step 18	Tips pretty much done! Just prior to final painting, there's some minor sanding and filling but it's 99% complete.