Today I began work on the other wing, which was in somewhat worse shape. The original builder had forgot to cut a groove for the servo wire before sheeting the core. So, he had gouged out a grove in the unsheeted section for the wire. I suspect I have a bit of OCD or something like it, as doing something like that would drive me nuts. It annoyed me enough that I removed a section of the sheeting to put a proper groove in for the wires. You can see, in the first picture, the original builders groove and mine. I have a hot wire cutter, but it's not really the right tool for the job, so I made myself a "hot wire groover". I took a piece of wire clothes hanger and bent it to the shape I needed, the attached it to the business end of a 25W pencil soldering iron. The contact between the iron tip and the hangar wire left a bit to be desired so it was slow to cut. Better contact, or a higher power iron would fix that, but it was sufficient.

With the groove cut and a pull string run through it, I put back the sheeting I took off. I must say that the sheeting on this wing was much better attached than the other. I had to work to remove the section I did. I was careful to keep the section I removed intact and undamaged so that I could put it back and not have to worry about fitting a new piece.

With the sheeting back in place, I cut a strip of styro to fill the original groove. Probably a bit over the top as you would never see the foam once it was covered. But, like a said, a bit OCD. Plus it was pretty deep in places and in the thinner part of the core so I did have some worries about the foam cracking there. The glue hasn't finished setting up in the picture and by the time it was done, it had pretty well expanded to fill all the gaps. I have since trimmed the overflow and lightly sanded the whole thing. It is still obvious that it is patched, but I'm happy with it.

Over the next couple of days, I cut an fit the cap strips for this wing and cut it out too.