Well, a couple more days of life happened. I spent one of them under my parents' house, repairing HVAC ducts that were chewed up by rats. If they can get to warm air, they'll chew a hole big enough to put your fist through. This is an 18" trunk line coming out of the furnace manifold, and the amount of hot air being lost into the crawlspace was impressive.
Attachment 27077
Check your crawlspace vent screens, people!
Anyway, this isn't a pest control forum...
I did another day of work sanding and filling the horizontal and vertical stab tips. I started out with this.
Attachment 27079
Then I formed it with a wood rasp to get this.
Attachment 27080
Then I sanded it with 100-grit to remove the rasp marks.
Attachment 27081
And finally sanded with 320 grit to eliminate the scratches.
Attachment 27082
There were still a few small divots and scratches left, so I mixed and applied a coat of SuperFil.
Attachment 27083
I'm not 100% certain, but I'm pretty sure I screwed up the SuperFil mix. The first batch I neglected to stir up the gunk at the bottom of the jar that had precipitated out of the hardener, and the second batch I think I mixed at 1:1 instead of 1:2. Good thing this stuff is only cosmetic! In any case, both batches have hardened just fine.
On the vertical, I followed the same procedure of rasp shaping, sanding and SuperFil.
Attachment 27084 Attachment 27085
While I had the SuperFil out, I took care of the areas around the door openings and rear quarter windows where the aluminum angle overlaps itself and leaves a small step edge, or where there were small voids.
Attachment 27086
Next up I got started on tips for the new elevator. I began by cutting two pieces of rigid insulation foam a bit wider and a few inches longer than needed.
Attachment 27087
Then I used 100-grit wrapped around the handle of a small pair of pliers to sand a channel in the foam to receive the steel end tube of the elevator, and cut away a bit of foam at one end to make room for the end of the elevator's spar tube.
Attachment 27088 Attachment 27089
Finally, I mixed up some Hysol and glued the foam blocks to the ends of the elevator.
Attachment 27090