Looking good!  All the time and hard work is now beginning to pay off!

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Sanding, sanding, and more sanding.
Now is when the earlier choice to use epoxy is coming home to roost. Using it, I was able to make a lot of progress pretty swiftly after picking this back up. But sanding that epoxy down to final dimension is Hell on Earth. I think I'm about 2 hours in with 80 grit and a tiny little wedge sanding block that I cut to fit into the vane crevice. The progress might be subtle, but I have the front corners sharpened up a lot, the frame has been worked down completely flush with the body, the inside face of the leading edge is smooth, that edge is *almost* a consistent thickness top to bottom (clean up to do) and I've decided that I need to sand the bottom edge level with the ground as datum, so that means sanding it at a downward sloping angle back to front relative to the pattern 

Looking good so far!! Slow and steady progress is the game with a project like this. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

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.

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.

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

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.

So not too far out then. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant