an airfoil for a gas turbine engine includes a substrate and a sheath providing an edge . a cured adhesive secures the sheath to the substrate . the cured adhesive has a fillet that extends beyond the edge that includes a mechanically worked finished surface . a method of manufacturing the airfoil includes the steps of securing a sheath to a substrate with adhesive , curing the adhesive , and mechanically removing a portion of the adhesive extending beyond the sheath .