Here is what we did to finish up the flaps. Eric layed up the tops and bottoms the bonded them together and foam filled them at the same time.
Then Ray Vinson recessed the ends and trimmed and trued the flaps for length and squareness.
Then I used the plasma cutter to cut out the sheet metal end plates and welded the 1" hex collars to them. They were then sandblasted to promote adhesion of the epoxy resin.
The next step was to make up some epoxy resin mixed with milled fibre. This was then used to fill the open foam and any low spots on the foam. The sheet metal end were then laid on top of the wet resin.
Then the exposed side of the sheet metal was painted with resin and a sheet of heavy bi-axial cloth was laid on top of the sheet metal end. Note that there was a hole cut in the bi-axial that fit over the collar and holes were cut in the sheet metal ends to key every thing together. We then cut out some tight fitting plywood plugs and taped them up with Mylar packing tape for release agent. These were then inserted into the ends of the flap, clamped up and allowed to cure.
Note the hex shaft was inserted though the assembly to ensure good alignment.
The next day we trimmed the flap ends and tried them out.
http://youtu.be/7J9faGWORBk