3M makes some thick but flexible clear tape that I used for gap seals on
my Decathlon elevator, and it made a huge difference. There's also the
much cheaper and colored versions of magic tape. A 0.5 inch gap seems
pretty big- Why don't they fit any more?

Those damned things have been repaired so many times, it's not even funny.

First the dzu connectors that originally joined the two halves wowed out the
holes over the decade(s) they were on the plane. When those holes got too
big, my A&P filled 'em in and re-drilled them for Phillips screws and
nutplates -- but, of course, the new holes might be a smidge off from the
original holes one way or the other....

Then, over the years since THAT repair was done, some nutplates have fallen
off (and been replaced), the new holes have wowed out (and been
re-fiberglassed), etc. Each subsequent repair introduces another variable,
and the end result is that the two halves firmly mate together, but with the
overlap between the two not quite so perfect.

The gap varies somewhat (the two pieces that mate are quite large) from 1/3
to 1/2", but with a solid "lip" of fiberglass backing the gap. The unit is
every bit as strong and sound as new, but that little gap just begs for a
piece of tape to smooth the airflow...
--
Jay Honeck
Iowa City, IA
Pathfinder N56993
www.AlexisParkInn.com
"Your Aviation Destination"