With everything primed, I was able to begin assembly of all the components for the right wing landing light. The first steps were to rivet the landing light bracket together. Next I have to but a slight bend in the bracket where the lens will sit. I pull out my bench vise and duck bill pliers to quickly get this done. Next I start to assemble all the parts for the lens brackets.
Once the brackets were assembled and the top bracket was installed on the wing, it was time to take a deep breath and trim the plexi to size. One thing I’ll note is that I probably cut my lens too narrow as I didn’t understand how it was going to fit into the hole. For the other wing, I’ll try to keep the lens near the 6.5″ width if possible. This may not be a huge deal, but worst case I’ll spend the $15 + shipping for another lens.
Lots of small cuts later, I have a lens that is just about the right size. I did end up putting in a small shim to help get a good tight seal, but not sure if that was 100% necessary. I’ll hold off judgement till I begin final assembly at the airport!
With the lens cut, I decide it’s time to move the leading edge onto the wing. The timelapse is amusing to me as I decided not to ask for any help. In the end I was able to slide the leading edge onto the wing spar and cleco into place. Once that was done, I removed the clecos and used the uni-bit to make the hole for the tie-down bolt. I made it 11/16, just like the tail-cone, but that could be too big if you want the bolt to snug to the skin. While I didn’t do it intentionally , that seemed to be just the right size if you use the Cleaveland tie-down bolts. I may 3d print a flange to hold stacked washers or something if I decide to go a different way in the future.
Lastly I take a LONG time to trim the landing light bracket to hold my Baja light. I was MUCH happier with right side vs the left as my first attempt was not as square as I wanted. Oh well.