Keep up the good work.  You will get there in the end. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Picked up and continued where I had left off, but we are VERY hot this week(current heat index is 98degF), so it's been uncomfortable to work for extended periods of time in my undonditioned workshop.

I made a mistake along to top rail between the first and second louvers that I'll need to revisit to correct. But other than that, slow forward progress. The largest change from last step is that the rear stile was sanded down flush. That opened up the visible gap at the rear a bit more than it already was, but it can get corrected now.

I have a tight, crisp fit along the left and bottom. The top and rear need more fiddling, then I'll be ready to move on to working the vanes smooth.

I was interrupted in the middle of sanding and immediately knew that I wasn't going to be getting back out to my shop tonighy so I snapped a quick pic where I was stopped.

Making steady progress!  The tags are a good idea so you can focus your attention for the next days work. Slowly getting there.  

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

More subtle changes. I filled in some low spots across the top and bottom, then did the bulk of the sanding across the rear upright. I'll have to iterate over it a few times to get everything dialed in, but now I have a better picture of where the lows are, where its highs are, and how I'll approach it.

Also pressed some putty into some tight lowspots in the front bottom inside corner. Those changes won't show in the photo, but there was some pocking and bumpiness along the vertical seam that I'm trying to get smoothed out.

Blue tape flags are pointing to the areas of focus for next round.

So not too far out then. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

No real visual change in the progress. I went all around the perimeter to make sure I had good clearance all around and the front was still about 1.5mm proud. So I sanded it down. It's still about 0.25mm up. I'll come back around to it after I give the remainder of the frame some attention.

Still progressing.  A bit of careful inspection may well find the area that is holding the front a bit proud.  Bit of sanding of the offending bit, once located, and you should be getting a better fit. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Here's how that turned out:
All work tonight was with putty. There was a chip in the top of the frame right at the mating point with the first vane. I epoxied from that point leftward, all the way down, then back across the bottom to the end of the first vane.

I also used the putty to build the bottom edge.

Still sitting a touch proud at the front.
I'm thinking something is fitting too snugly to get the edge to sink down. I'll be taking a closer look at that tomorrow as well as skimming the top edge with putty to fill in all the low spots. I've been eyeballing vane #2 and thinking I might want to give it the same treatment I gave #3 and #4. It's edge curvature is looking a touch out of place.

I hope I didn't just mess something up. I broke out some SteelStik epoxy putty to fill in the missing edge on the very front of the pattern. It filled it in, but I'm a touch worried that it isn't going to hold the underlying epoxy properly when it cures. About 15 more minutes until I take a file to it to reset the edge.