Category: Landing Lights

Outer Leading Edge – Part 8

Brian 0 Comment Landing Lights, Outer Leading Edge

Circling back to finish the landing light lens. With the experience on the other lens, I’m ended up cutting this lens to the “proper” dimensions this time. (The directions are correct even if you don’t think they are. Go figure!) Still debating if I will purchase a replacement lens for the right wing or not as the other does work just fine.

With the lens cut and fitted, I go ahead and mount the landing light in the wing (off camera) and struggle to figure out how to actually screw in the landing light lens as I can’t get behind it to apply any pressure. The lightbulb moment was when I realized I needed to use tape on the lens to help provide the outward pressure so I can screw in the lens.

With the lens installed (and protected by additional tape), I then got some assistance from my wife to cleco the leading edge to the wing spar. Getting the ribs clecoed into place I then begin riveting the leading edge to the spar. As a small note on the blind rivets, not sure if it’s just my blind rivet squeezer, but I really don’t like setting blind rivets.

With all the ribs riveted to the spar, I squeeze the skin rivets then ask my wife for assistance to rivet the top of the leading edge. Easy enough and once done I get to stand back and admire my progress. Plan on getting the other wing done shortly as I approach my fuselage crate date.

Landing Lights – Part 3

Brian 0 Comment Landing Lights

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.  

Wings – Odds and Ends

Brian 0 Comment Landing Lights, Outer Leading Edge, Top Skins

Well, I’m getting to the point where I was expecting that I would be putting in my fuselage order, however I’m not quite as far along as I wanted to be.  Granted, working on the wings is a slog and at points I really need a second set of hands.  I was spending a number of weekends working on my IR this year, and spending time with the family.  Overall it’s been pretty busy, but I’ve accomplished a lot outside of my -10 build.  

So looking at what I still need to get done, and the calendar, I realized I’m running out of opportunities to prime parts.  Amazingly there was a forecast day of 60+ degree weather with average humidity.  Decided I needed to just knock out a few things including priming. 

I revisited the rivets on the outer leading edge that my EAA tech counselor pointed out and marked which ones needed to be drilled out or just get another hit with the rivet gun.  Then with the help of the wife moved the wing so I could get access to the skin followed by fixing all the “problem” rivets on the OLE.  

Prep for the skin was pretty easy.  Verified that all the holes were deburred, edges were deburred and used my orbital sander to give a slight scarf on the skin edge per the plans.  (I was not super aggressive so I’m sure the joint will be visible.  Honestly don’t think it’s a big deal).  Then using a ScotchBright pad and the orbital sander, I lightly scuffed the whole skin.  

Next I prep all the landing light parts.  Mask off the front of the light housing to be more reflective?  Not sure it’s helpful, but I like the way it looks I guess.  (Sorry didn’t film the priming, but it’s just a wipedown with acetone followed by AKZO spray primer outside).  

Landing Lights – Part 2

Brian 0 Comment Landing Lights

Next step is starting to install the landing lights on my right wing.   Again this is the Landing light kit by DuckWorks aviation.  Just like the last time, I lay out the template on the leading edge, aligning it on the rivet lines, etc.  I then drill the four corners using my uni-bit to make some starting holes.  

Next I transition to my harbor freight saw to make the rough cuts.  I’m still having a little difficulty controlling this saw so I keep things fairly rough and then follow up with the pnumatic nibbler.   Next it’s on to the files to get everything even and smooth. 

I then fabricate the light bracket and get the angle aluminum trimmed to size and drilled, followed by getting the nutplates installed on the leading edge.   Next it’s time to drill the lens attachment points and to get the attachment hardware all set up and preped for priming.  

I also mask off the acrylic lens with painters tape and get it marked so I can begin trimming it.  (More on that in one of the next videos).  I did verify that my metal bandsaw blade cuts the acrylic well!

Landing Lights – Part 1

Brian 0 Comment Landing Lights

I think I mentioned this in an earlier post, but I decided I was going to go ahead and get the DuckWorks leading edge landing light kit.  Others I talked to were trying to put their landing lights in the wingtips (FlyLeds now offers this as an option!) but I ended up deciding that the leading edge design was good for me.

I purchased the “blank” kit from Duckworks as I planned on mounting one of the Baja Designs LED light kits.  After a bit of debate, I did purchase one of the Squandron Pro lights so I could do all the fabrication necessary for both wings.  I’m holding off purchasing the second Squadron Pro until a little later in the build. Read more