ORIGINAL: Sport_Pilot
I have a Koas which has some large gaps between the saddle and wing. I was going to put Saran wrap on the wing and bolt it down, then fill the gaps with microballons, maybe add a small amount of fillet while at it. Should this work, or do I need some of these fancier methods?
Actually, that is pretty much the proceedure used to "pot" at wing in place. You can start off putting a bit of the fillet material on the wing saddle first - helps assure a surface - then bolt the wing in place (Saran wrap [or I prefer monokote backing] on the wing of course). Bolt the wing down - the excess fillet/potting material will ooze out. You can then fill from the outside and build a fillet as desired. This results in a wing that fits perfectly when done. This proceedure is something we find pretty important with pylon planes - if the wing does not fit well, it will vibrate in the saddle, bolts with come loose - and sometimes the wing rubbing on the fuselage will actually burn the wing mount area.