Plastic flaperon tips

[colospace]

Has anyone installed the factory optional plastic flaperon tips?
Looks like their outer profile matches the outer profile of the flaperon (i.e. it is not intended to slip inside of the flaperon skins). There is no "mounting lip" formed into the part.
Also (in a plan view), there is little taper toward the trailing edge and a relatively small radius at the aft end. I'm cogitating on how to make this gracefully blend into the flaperon trailing edge.
Just wondering how others may have handled this before I start messing with the parts.

[HighWing]

Gary,
I will tell you how I would do it. I would first scuff sand the entire outer surface of the tip and the surface for a half inch or so inside the flaperon to create a tooth for adhesive. Then using the Hysol cover the edges and squeeze the sides so it will fit into the flaperon. Clean it up a bit and let it cure there. I would then use Micro or Superfil to fair in all surfaces to get a continuity with the tip and the outer flaperon skin. I can't imagine where the tip is in relation to lots of very delicate parts - trailing edge for example - that it wouldn't last the life of the airplane in original condition.

[n85ae]

What Lowell suggests is the way I did mine.

[colospace]

My current thinking (to preserve the existing good outer profile match and fit at the leading edge) is to bond a 3/8" to 1/2" plug of balsa/basswood halfway into the end of the end of the flaperon and bond the tip onto this "lip".
Then do a little SuperFil and trimming at the trailing edge.

[n85ae]

Then you will have the opposite problem that the tip is then outside the flaperon skin. Better solution is to mark a reference line on the tip with
pencil and with a sanding block sand the tip where it inserts and remove
the sheetmetal's thickness of material. This will make it so the outer part
is flush where it meets the metal. Then do what Lowell says - Hysol it in
place.

Regards,
Jeff Hays

My current thinking (to preserve the existing good outer profile match and fit at the leading edge) is to bond a 3/8" to 1/2" plug of balsa/basswood halfway into the end of the end of the flaperon and bond the tip onto this "lip".
Then do a little SuperFil and trimming at the trailing edge.

[n85ae]

Ten years later - As I recall I cut the trailing edge of the tip open and bonded
in a piece of aircraft ply. Then sanded this to form a proper trailing edge