Originally Posted by kmbusse
Does the cover go over the fairing opening and then mounted in with more fiberglass, or does it get sanded down to fit inside the fairing to sit flush with the edge of the fairing and then mounted in?
I suppose both will work, but the first way is much easier: spot-weld an oversized piece, fillet the inside with flox, cut/sand away excess. Exactly as described in the manual worked well for me.
2-ply glass is quite thin if you lay it up between two pieces of plastic sheeting
and squeeze out excess resin. Let it cure between plastic sheets: it results in stronger epoxy and stinks less. Sheeting will come off with no effort once cured.
If you are new to fiberglass here are some tips I wish someone told me before my first attempts:
- it cuts with tin snips, gelcoat no problem;
- diamond dremel wheels shape it quickly and won't go dull;
- sand/grind wet to control dust (mister not bucket if electric tools!)
Finally, be prepared for the esthetics of the fairings to be inferior to the rest of the kit. It would take insane hours and lots of micro to make Van's fiberglass blend in nicely with metal--and each other for that matter, see Tom Martin's tip
(sadly his photos seem to have disappeared).