3.7 Hours -
Building the wingtip nav/strobe lights is taking longer than I thought it would, but I’ve been having fun learning how to make them, and then actually seeing them come together. After today’s work session, the left light is essentially complete (just waiting for the strobes to arrive) and the right tip insert is ready to have the LEDs glued/wired to it.
I started off the day by finishing the edges of all the mirrored plexi pieces for both wingtips. In addition to finishing the edges, I cut 1″ holes in the pieces that will hold the strobes. I also cut an identical 1″ hole in the aluminum insert and the wingtip itself. The strobe tube will be held in place by 2 screws, but I’ll wait until I have the strobes in hand to drill those holes.
The left wingtip insert after cutting a 1" hole through the plexiglass and aluminum for the strobe light.
Next, I cut a hole in the left wing tip where the LEDs will be. This allows for airflow around the aluminum cutout, cooling the LEDs. I’ll also install a heat sink on the aluminum behind the LEDs, but they haven’t arrived yet.
I cut out the majority of the wingtip on the LED side and put a matching 1" hole on the strobe side.
Once the cut-out was completed in the wingtip, I installed platenuts for attaching the aluminum insert. I decided to use six platenuts per wingtip…three on the LED half and three on the strobe half of the aluminum insert.
At this point, I was able to install the left nav light setup (minus the strobe) in the wingtip and get my first real look at the, more or less, completed product. Sure, it could be better, but I’m happy with it as my first attempt.
After cutting everything, the first test fit looked good.
Another view of the left wingtip with the insert screwed on.
One more view of the left wingtip...this one has the mirrored plexi in place, but the plexi still has its protective covering attached.
With the left side waiting for a heat sink and strobe tube, I started working on the right side. As with the left, I bent the aluminum insert to fit the wingtip cut-out. Then, I started drilling holes to mount the aluminum piece in the wingtip and for attaching the mirrored plexi over the LEDs. Since I had the left side built and now know how they go together, I was able to drill a few more holes on the right side now, which I waited until the end to drill on the left. The right side is now to the point where I’m ready to glue and wire the LEDs in place. Getting to this stage on the right side took less than half as long as it did on the left side!
The right wingtip insert in now ready to have the LEDs glued and wired.
