Today I worked on the LED nav lights, and got them done to the point that they are ready to install for good when the tips are ready to go on the wings. This was a REALLY fun project with huge results and satisfaction when I finished! There are a BUNCH of pictures from today!
I started by cutting the hole in the right aluminum back plate for the wires and heat sink to go through, then matched that up to the wingtip, and marked that hole to cut.
Next, I cut the hole in the mirrored plexi that will hold the strobe light. I started with a tiny drill bit (can't recall what size, but smaller than 3/32), and worked my way step by step until I got to a 1/4 hole. At that point, the fly cutter was used to open the one inch hole needed for the strobe base.
Then I drilled it for the screws that will hold the base in place (the pic is really fuzzy, sorry!)
Then I used the strobe plexi as a template to mark and drill the holes in the back plate and fiberglass.
Then I fit everything in place, and lit the starboard side up!! This seems like it happened fast, but it actually took about two hours to get to this point.
Then I took it all apart for two reasons. One so that I can use the back plate as a template (in reverse) for the left side, and two so that I can finish the wingtip installation without scratching or damaging anything.
On to the port side!! Here's a pic of the back plate all drilled out with the fiberglass marked for cutting and drilling. The left side was much quicker since I had a guide to go off of.
I took a few more pics of the red LED's. I wish I would've done this for the green one's, but I didn't think about it. I dimmed the lights a little when I took the last two. We'll do a full lights out picture after I get the lenses cut and installed.
I LOVE how the light is picked up by the edge of the plexi!!! SWEET!!!
I hope maybe a day or two more, and the LED/strobes will be finished up!!
CJ
