Hey Scott,

I have been doing my fillets with tape evenly spaced, one piece on the tube and the other on the fin. On the fronts and backs, i lay tape at an angle, so the side of the tape just comes in front or behind the fin. After tapeing up two fin acrossed from each other, I level the tube and turn so both the fillets are the same on the clock face, like 10 and 2, if looking at the aft end. I drip the epoxy onto the filet area, letting just alittle dribble, try to catch the runs quick with little rips of paper towel. Then when i get a skin on the epoxy, I pull the tape back at a 45 degree angle. I sand with my finger in the paper, till i like how she looks.

I use the Aeropoxy which takes hours to set up. I create a target trough bordered by tape, doing two adjacent fillets at once. As above, you need to lay the rocket flat. I put in enough epoxy and use a round object to smooth the fillet curve (old D, E engine casings work as do old prescription bottles, etc.) With the Aeropoxy it will flow and remove bumps before it sets up (3-6 hours or so depending on room temp) I yank the tape off and smooth down the edges with a finger when it's gelling up.

Aerpoxy slow cure needs patience, but it seem to harden exceptionally well. It takes at least 6-9 hours to harden, but appears to cure for an even longer period of time.

If you're in a rush don't use it. I like it, but I'm used to it. You can get it from GLR. It is tough.

I'm usually not that patient. I'll use tape to protect the areas where I don't want fillets, like David. I like to use West Systems thickened with 404 filler to just a little stiffer than mayonnaise, but not as thick as peanut butter. It stays where you put it, but remains amenable to shaping with a finger wetted with alcohol plenty long enough to get them smooth and consistent. THen remove the tape and smooth down the edges. I can usually do all six at once and not have to worry about them sagging or running. Just have to be careful to not put finger dents in the ones already done.

I thicken the heck out of the epoxy until it's stiff enough to not run (usually with colloidal silica), and then I do all of my fillets at once.

Like others, I thicken it enough to do them all at once. I use tape on the edges, and a short chunk of pvc pipe (1/2 or 3/4") dipped in alcohol to run along them to spread and smooth. Just keep wiping off the pipe to keep it smooth. Generally needs little or no sanding afterward, maybe just where the tape was, to get rid of the edge.

Ken

This has some pictures that might help show you what I do. I make the inside fillets with something close to applesauce and the external ones just a little thicker.
http://picasaweb.google.com/jamesr2/Intimidator4ModificationAndBuild?authkey=Gv1sRgCPzuhq-kzYH0zwE&feat=directlink