A seal has to run down both sides, and 1/8" ply is not wide enough. My solution is to glue more ply on the inside. I added three layers, with each layer just a little further back, so I could sand it parallel to the skin that will be put there.
This process took several days, and many many clamps.
Time for the first side of skin.
Trim to shape. I used an 8' aluminum ruler to find the trim line.
Installed the second side and trimmed.del
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