We brush a THIN layer of hy-sol onto the skin so it will rapidly and completely bond to the sother skin and spar. Remember, we rough up the carbon fiber pretty good with sandpaper to get off all the extra resin so the hy-sol can bind right to the carbon fiber itself. We then want to apply the hy-sol to wherever it WILL contact the other skin and spar when we put the two pieces together in a few moments.

The elevator upper and lower surfaces now bound, we cut out the back for the trim tab. This is a hearing-protection job since that pnuematic cutter is SO loud, and a mask-job because it throws out a bit if dust.

OK so now we glob the hy-sol onto the trim tab.... it is like really soft, melty peanut-butter in consistency... really easy to work with.

And we shape the hy-sol just perfectly to attach the upper skin of the trim-tab.

And we use this hinge for the trim-tab... a lot of backplates there! That represents a few hours of work.

Now we grind a hole in the elevator for the little trim-servo to go to live!

We grind it pretty straight.

And then sand it super-straight! The elevator trim servo, sitting at right, will go live in that hole to actuate the tab.