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I'm working on the lower vertical stab piece. Of course it doesn't fit. The picture makes it look worse than it is, but you can see that it forms a 'hump' in the tail.
   
If I were to make the leading edge straight, look closely and notice that the holes are right on the edge of the vertical stab.
   
...and there is a huge gap at the bottom.
   
Zenith 750 Cruzer Just like everything else in life I guess, if you want it done right, you gotta do it yourself!

So I cut an oversized piece out of my old vert tail skin. You can see the old piece laying inside the new piece.

   
Zenith 750 Cruzer Now I'm making a paper template to get an exact fit. This is harder than it looks-I made three paper templates.
   
Zenith 750 Cruzer Now I will trace this onto a posterboard and cut it out and see how it all fits. I can make any fine adjustments and then trace it onto the new aluminum piece.

Once the new piece is on, I will make a fiberglass fairing that goes all the way around the bottom, curving around the top and bottom of the horiz stab. I should pick up another 30-40 kts with that fairing!

   
Zenith 750 Cruzer The paper is traced onto the posterboard.
   
Zenith 750 Cruzer The stab is centered with the fuselage. I also taped some blocks and L angles to the top of the fuse to hold the sides of the paper in to where they should be.
   
Zenith 750 Cruzer I had to make 4 of these posterboard templates with little refinements to each one.
   
Zenith 750 Cruzer  
   
Zenith 750 Cruzer Now there is no hump in the stab.
   
Zenith 750 Cruzer The part right in front of the horiz stab is cut straight down instead of continuing under the stab. The reason is because I want to be able to remove the vert stab once this piece is riveted on. If it continued under the stab, I could not do that. All of that space will be covered with a fiberglass fairing.
   
Zenith 750 Cruzer  
   
Zenith 750 Cruzer Now I'm tracing the pattern onto the aluminum.
   
Zenith 750 Cruzer After cutting it out on the bandsaw and filing and sanding the edges smooth, I'm left with a very nice fitting part.
   
Zenith 750 Cruzer I drilled the holes now so that once it's held in place, I can match drill it to the vertical stab.
   

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