Graybeard & Opjose,

Fair enough, I certainly accept the argument that this may not be needed on all types of planes. With that said, the gap is already sealed so the question of why I did it to begin with (while it teaches me a thing or two about plane set ups) doesn't address my immediate problem .

At this point I have two options: either remove the seal it or fix it. Removing it would be somewhat problematic and probably the easiest way would be to cut at the bottom of the "V" along the surface gap. But in the spirit of learning for when/if I decide this is really needed and helpful, I ask that you and others who have been doing this much longer than I give me some advice on the proper procedure.

I am really intrigued by Graybeard's idea of covering everything with one piece! I will think about it for my 4*-Sixty kit. If I understand your process correctly, you assemble the plane completely (surfaces, hinges and everything), and then you cover with one piece. This indeed would inherently elimintate all the gaps, but in essence, the process would still involve covering the surface gaps; but instead of doing it on top of a layer of covering, you do it directly on the wood as part of the initial covering. If my understanding is correct, then can you please explain your process of sealing the gap when you cover the plane? This could help me understand what I am doing wrong.

Thanks again.