Brief Description: Van's Official Response - Not a problem
While it took about half a dozen emails to get Ken Scott to understand the problem, he finally answered my question on whether the 1/8" gap at the end of the spar that starts about 2" from the end of the spar and separates the spar and the spar extension is a structual issue or not.
Here is his response:
"Bob: if you mean that the flange width tapers slightly toward the end of the spar, that has no significance at all. Nor does a gap between the end of the spar the 1006 extension. As long as the flanges present a flat plane to the skin and holes line up with the holes in the skin, all is well."
Brad and I pulled the skin off the shelf and everythign lined up. So moving ahead after losing a week on this issue.