The first challenge in this step was to understand how to understand how the winglet trim template is to be positioned on the winglet. There are at least two ways to interpret the instructions here:
- Align the TE and the LE of the template:
- Align the bottom of the template to the bottom of the winglet. To do this it’s neccessary to “roll” the template around the bottom edge.
As indicated the difference is substantial here.
I raised a discussion on the Cozy-group and the answer was to use the second approach. This may be obvious, but I had to check this before I started to cut off the piece.
I tried to use a coping saw as suggested in the plans. However I soon changed to my band saw to get as accurate cut as possible. I had to manually trim off the glass around the coax cable.
2019-11-21: Jigged the upper winglet to the wing as per plans. Had no one to help me here so it was a bit more work than aticipated, but it went ok. I took out some of the single wires from a network cable to use as measurement guides. I tried several other approaches but these wires was without any flexing.
To cut the wing I used my jig saw with a fine tooth blade. The blade was not long enough to reach all the way through at the thickest portion of the wing. I then had to remove the foam as deep as the cut was, then use the jig saw upside down. It worked very well.
The last step was to prepare the wing for turning. I had to add some height to the jigs to be sure that the winglet came clear of the floor.