LOL...I know what you mean about butchering wheel wells!

I finally broke down and bought a Weller pistol-grip soldering gun. I removed the tip and replaced it with 1/8th inch copper wire.

This wire was bent into a rectangle the exact width of my wells. Once I trimmed the skin away from my cutout pattern on the wing panels, I simply melted my way down to the proper depth and twisted the rectangle around in a full circle. In order not to melt too deep, I placed ply stops across the rectangle at my desired depth. This way, I wouldn't have to worry as I twisted the gun and wire around. I did this on my Kaos 90 and it produced terrific results.

I can't take credit for the idea, though. Wing Manufacturing had this hint included with a set of cores I picked up a few years back...

:-)

PM