Trimmed the hinge pins to length. Inserted pieces of nyloseal to run hinge pin through from end keepers to the first hinge. Floxed same into the winglet as well as the keepers into the winglet top tips

Made up temporary rudder cable ends. Ran the rudder cables through the conduits and test fit / "waggled" the rudders. A small clearance adjustment is needed on the left winglet, otherwise, they work great.

Drilled holes in the winglets and rudder for the return spring tubes and hooks. Floxed both into both winglets and rudders. Peel plied the tube in the winglets and cleaned up.

Filed the edges of the winglet and rudder recess layups. Test fitted the hinge pins and continued filing until the rudder closed 100%. Opened the holes in the winglet top ends for pin clearance. Dremel routed the inside stop for the HRBH.

Filed the edges of the recently laid up rudders until the fit properly into the winglet slots. Inserted the hinge pin and checked throw.

Removed box sealing tape from the carbon hinges. Filed the edges of the rudders and winglet cutouts. Test fit the rudders back into the winglets. Filed the ends, sides, hinge ends etc. until fit well enough to insert the hinge pins.

Measured and cut glass for the 3 ply recesses in the upper and lower winglet. Wet glass, microed the foam, floxed the hinge edges, added 2 ply strips to the hinges then added the 3 ply recess layups. Added some small peel ply strips and cleaned up.

Did a 2 ply BID layup in the HRBH recesses, 3 plys on the ends of the upper and lower winglets. Added a couple small pieces of peel ply.

Dremel routed the HRBH recesses to final depth. Measured shapes and cut glass for the layup in those and at the ends rudder recesses in the winglets.

Knife and scissor trimmed the rudder recess layups.

Did the 3ply BID front and ends, 2 extra over the hinges layups in the left and right rudders.

Finished making paper patterns for the rudder recesses. Cut glass for those layups & set up the table for layups.

Made paper patterns for the layups in the rudder recesses.

Did a 2 ply BID layup onto the bottom of the 1/4" ply hook holders for the rudder return springs

Made piano wire hooks for both ends of the rudder return springs. Made plywood circles with slots for the winglet ends.

Vacuumed the hinges and winglet / rudder recesses. Floxed the hinge pieces to the winglets & rudders, then clecoed and clamped them in place. Cleaned up.

Re-drilled the center hinge on the right winglet for better fit. Sanded & filed the recess at the top of the left winglet. Sanded all hinges then taped their ends for layup protection.

Made rudder return springs. Test fit the bellhorns one final time then floxed them into place.

Drilled holes from the hinge line to the winglet tip in both winglets. Used a countersink and drilled larger holes at the tips for the Carbinge keeper ends. Cut the keeper hinge pins to length and test fit. They all fit great!

Finished making the HRBH recess. Measured, marked, drilled holes for then test installed with clecos the hinges for the right rudder. Adjusted the HRBH fit with tape piece until it was aligned correctly. Cleaned up.

Started making the recess in the right winglet for the HRBH with a hole saw.

Cut hinge material to 6" & 4" length pieces. Measured, marked, drilled & clecoed in place 3 hinges in the left rudder. Measured travel, looks good.

Adjusted the recesses in the left rudder for the hinge. Test fit the hinge, measured & marked its location, drilled 3/32 holes and installed same in the rudder & winglet with clecos. Checked travel.

Finished sanding the foam from the right rudder recesses. Removed a foam chunk for the placement of the HRBH and installed same with two screws temporarily. Marked spots to remove the outer skin if necessary to access the HRBH voids for installation.

Sanded foam in the edge recesses of the right rudder.

Marked then cut out the right rudder. Began carving and sanding the foam recesses in the winglet for hinges, etc.

Did the right lower winglet attach layup. Added peel ply.

Sanded surfaces for the right lower winglet attach layup. Measured and laid out glass for same.

Added peel ply to the layup just done.

Did layup #4 on the right wing.

Cleaned up for the next layup.

Sanded the wing and winglet in prep for layup #4 on the right wing. Filled the epoxy pump.

Sanded the foam piece inserted between the upper and lower winglet on the right wing. Added another piece of foam there. Cut waxed paper patterns and glass for the next layup.

Continued working on the recess. Test fit the HRBH into the rudder. Cut a hole into the wing for clearance for the end of the rudder conduit.

Continued cutting, chiseling and sanding a recess in the winglet for the HRBH cable end.

Started cutting, chiseling and sanding a recess in the winglet for the HRBH cable end.

Removed glue and wood braces (all but larger one) from the right wing and winglet. Aligned the trailing edge, was bent, used a heat gun. Cleaned up.

Finished sanding and filing the right lower winglet to shape. Sanded the bottom of the upper winglet and outer layups. Microed the lower winglet onto same; weighted it down, removed excess micro clamped the trailing edge and cleaned up.

Made another sanding depth jig and finished sanding the foam edges of the left rudder.

Continued routing & sanding the 1" and .6" slots in the left rudder and winglet. Filled some voids in the right wing outside layup.

Hot glued sticks to the upper right winglet for alignment. Fein sawed, cut, filed & sanded the right lower winglet to shape for eventual mounting.

Routed out foam from the rudder recess. Made a sanding block and sanded the channel smooth and to depth.

Measured and marked the cutout for the left rudder. Fein and hack sawed the piece free from the winglet. Cleaned up.

Trimmed the previous layup and cleaned up.

Sanded the lower winglet joint. Trimmed glass from previous layups. Laid out glass, made waxed paper patterns then did the 1 ply BID layup to join the lower winglet.

Cut glass. Laid up individual pieces and assembled onto BID. Epoxy painted wing & winglet, microed foam then added layup to outside of wing / winglet. De-bubbled, added peel ply and some tape and cleaned up.

Marked patterns using the other side of previous patterns for the right winglet layups # 1 & 2.

Made wax paper patterns. Laid glass onto them, assembled the layup one layer at a time. Painted epoxy onto the wing / winglet, added the layup, de-bubbled, added peel ply and cleaned up.

Cut glass for the outside layups on the left wing / winglet. 36-grit sanded the surfaces dull as prep.

Trimmed the previous layup on the right wing / winglet. Sanded block A to shape, dulled the wing / winglet surface for the next layup.

Did the right wing layups #1 & 2.

Cut glass for layups 1 & 2. Re-routed antenna wires and set up the shop for layups.

Made the remaining flox corner; made paper patterns for BID layups 1 & 2 for inside layups on the right wing.

Finished carving foam. Made foam inserts, block A and half of the flox notches for the inside layups.

Started carving the foam for the right winglet inside layups.

Fitted the right winglet to the cut section. Adjusted to correct measurements, clamped in place, then hot melt glue it in place with extra cross-bracing.

Cut the extra foam away & sanded smooth the foam used to fill the slot on the left winglet. Cut the piece from the right wing marked in previous sessions.

Built a jig to hold with right winglet in place for alignment measuring. Clamped, adjusted, measured and repeated until it was dead on then drew a pencil line to cut the piece out of the wing. Microed a piece of foam to the slot in the left winglet on the outside.

Finished carving the right winglet to shape. Made a fixture for the wing reference point.

Set up the right wing. Hot melt glued the aileron in a fixed position. Sanded the lower end of the right winglet and marked same for the LE cutout.

Cleaned up from the previous layup. Flipped the wing over and made hangers for the right wing.

Microed the left lower winglet onto the wing.

Made paper patterns for the inside left wing layup.

Fitted the lower winglet to the wing. Added some wood strips for alignment, then cut the glass, carved the foam and repeat to fit.

Knocked the wood braces off the wing. Turned it over with help, removed all the hot glue residue and starting making a paper pattern for layup #4.

Did the 2 ply BID 7 ply UNI layup on the bottom of the wing / outside of the winglet

Finished making paper patterns for layup #3

Finished carving & sanding block A and surroundings. Started making paper patterns for layup 3.

Finished trimming the inside layups. Carved & sanded block A to shape then sanded the wing and winglet with 36 grit for the next layup. Re-routed the antenna cables to the wing root.

Continued trimming the inside layups

Started trimming the inside layups for the next step

Did the 8 ply BID layups #1 and #2 on the left winglet to wing attach, added block A with micro, screwed & weighted A then cleaned up

Made paper patterns then cut glass for the winglet attach layups #1 and #2

Carved the 1/2" deep slots for flox corners

Finished carving & sanding foam for the innner winglet layup filler pieces

Carved the 2" recesses for the 8 ply BID layups then cut and carved foam block A.

Hung straps from the ceiling. Suspended the wing from straps, turned it over and began carving foam for the inside winglet attach layups.

Added some conduit straps to hold the antenna extra wire.

Added some additional boards to brace

Adjusted winglet until measurements were dead on. Marked wing and removed tip section per plans. Re-placed winglet then hot glued boards on to it to stabilize for next steps.

Made a wood and copper piece to mark the measuring point. Cut a recess for the coax coming out of the winglet. Clamped and re-clamped the winglet until all 3 measurements were close.

Set the left winglet on the wing and started checking measurements. Cut a notch for the antenna coax to clear.

Put the wing on the jig table and braced it. Added weights. Marked one upper winglet for trimming.

Did the 2 ply UNI layup on the inboard side of both lower winglets. Added peel ply, taped the edges and cleaned up.

Sanded the edges and trailing edge of the lower winglets. Cut glass and peel ply for the next layup.

Did the 2 ply UNI layup on the outboard side of the lower winglets

Made platforms for the lower winglets to sit on during layups.

Sanded the bottom edge of the lower winglets round. Made a paper template then cut glass for the outboard layups.

Removed the plastic and peel ply from the winglets layups & cleaned up.

Added peel ply & plastic. Taped the peel ply and plastic tight. Clamped straight edges to the trailing edges, inserted them into their foam blanks then added weights & cleaned up.

Did the 2 ply UNI and 1 ply BID layups on both winglets.

Made wood strips for trailing edge of winglet clamps. Trimmed foam blanks to fit same.

Sanded the antenna covering foam smooth. Sawed off the fish tail and faired in the trailing edge on both winglets.

Added micro over the recently inserted balun and cables, then, placed a 1/4" square piece of foam to fill and cover same.

Marked the antenna locations in both winglets. Routed channels for the RG-58 in both winglets. Made the second antenna then installed both antennae in the winglets and cleaned up.

Made one of the antennae for the winglets

Epoxied the first ply on the winglets, then added the 2nd ply of UNI, the BID, the peel ply, some plastic & put them in their blanks with weights for cure

Trimmed the foam blanks to do the outside winglet layups. Added micro and the first layer of UNI.

Cut the lower piece out of the right winglet. Begain fitting same to wing by cutting relief for the antenna wire.

Cut the foam blanks for the winglets in half with a hot wire cutter. Micro filled the screw holes dents and dings in the winglets.

Carved & sanded the winglet tips to shape.

Microed the 2 larger winglet foam pieces, joined them with screws. Made a 1" foam block for their tips then microed and screwed those onto the tips.

Dug out the winglet foam pieces and dry fit / test assembled them.