Duane,
There's a lot going on in your message. Maybe I can help.
dwilson said:
I am ready to rivet the trailing edges of my elevators and glue in the foam ribs on the trim tab.
Why use foam? I would install small aluminum ribs. It's probably more work to make, but less work to finish and it will last forever. Whatever you stuff over the foam (slurry or flox) will eventually crack and the paint will chip. Aluminum and fiberglass have different coefficients of expansion and cracks are inevitable.
dwilson said:
Another thread mentioned RTV instead of ProSeal. Said to "be sure and get acid free"
Three things here. First, I would never put RTV where you want to paint. Paint just won't stick to it and even if it does, it won't stay there for long. Two, RTV will not hold as well as ProSeal and is generally, not that good of an adhesive in this situation. The RTV will allow the part ot move just slightly, thus assisting in the aforementioned cracking. Third, acid-eating RTV is an urban legend. When the RTV sets, it is basically inert and no threat to "eat a hole in your aluminum" as the legend goes.
dwilson said:
Went to the automotive store today and looked for "acid free" RTV. The guy looked at me like I was from New Orleans. He sold me a tube of RTV. I plan to use this on the trailing edges tonight. Can I use it on the foam ribs too, or will it melt them?????
Yes, RTV will dissolve certain foams. It all depends on what you are using. All round, I don't think you'll be happy with foam ribs but it's your rig, do what you'd like. A previous poster mentioned using flox as a cover. You can do that but that stuff is a real bear to sand and that's not really the intent of flox. What you really want is a dry mix of slurry (microballons). I would cover it with one layer of glass cloth first before applying any surfacer as this aids adhesion.
(Graduate of the Rutan School of Fiberglassing)