I recently bought the Ductworks Aviation Leading Edge Landing light assemblies. I went with the blank sets, as I plan to use an LED solution for my lights.  I was extremely nervous about making a cut in my beautiful leading edge! I started by measuring from the seam of the top skin to leading edge skin, and from the centerline of the inboard rivet row and marking the lines.  Next I applied the cutout form temporarily to line everything up. Then I measured again, and consulted photos online. I really didn’t want to mess this cut up!

Then I marked the area to be cutout and hatched the inside area with a marker. 

I used me new dremel to make the first rough cut.

I slowly worked my way from the rough cut to a finished edge using a combination of tools in the dremel as well as hand files and sandpaper. I’m very happy with the finished edges. 

After I got to a point I considered to be complete, I re applied the template to check for any inconsistencies. I found a few areas that could use additional work and marked those in blue. 

Here is the final FINAL product of the cut. 

Then I turned my attention to attaching the lens to the leading edge. I first hit the reinforcement pieces with the scotchbrite wheel, and then I drilled the appropriate holes that will hold the screws.

Then it was time to attach the “rib” that will hold the actual landing light. There is a template for this as well. I used the template to mark a bit of cardboard so the template would remain in place.

Then after drilling, I clecoed the nut plates in place and drilled. 

Here are the nut plates after drilling and riveting with pop-rivets. Drilling the inner rib was challenging. I used my 90 degree offset adapter in order to drill.

My final task for the session was to cut the plexiglass to size. I first marked for the cut according to the instructions and then using the dremel made the cut. 

Pictured here is the rough cut. I still need to clean the edges properly to prevent cracks.  In the meantime, I’m off to Santiago Chile, and Lima Peru for some vacation!!

First order of business for today was to move my empennage to the new hangar.  Previously I had created a way to hang the tail feathers from one of the beams.  However, the beams in the new hangar are wider, and lower.  It didn’t require much of a change though. 

I had to install two bits of two by four to ensure the parts remain level and don’t fall with the additional width of the beam.  I still need to secure the vertical stab as I always worry that its much more prone to falling than the horizontal stab.

Next up I finished the riveting of the aileron gap fairing and flap brace for the right wing.

I swapped the wings and completed riveting the top skin to the rear spar on the left wing. I used the mushroom rivet set and tungsten bucking bar. 

Next I I countersunk the aileron hinge brackets, and riveted them together. 

I riveted both aileron hinge brackets to the rear spar. AN470 4-7s are just a tad long. A 6.5 would be perfect, and if you make a small riveting mistake its easy to get a bad shop head. 

My final task for the day was to begin fitting the aileron gap fairing and flap brace on the right wing. 

Today I started with riveting the right wings aileron brackets.  This required me to do a quick countersink for the rivets closest to the bearings.  The flush side of the 426 rivets should be towards the outboard wing tips.  Then I placed the bearings in place and riveted the brackets.  This took some finesse as the AD426 4-11’s are long!  I had to play with several setups before I found a yoke and rivet set combination that could go allow enough space. 

I slightly over-countersunk one rivet.  Its not drastic enough that I feel compelled to replace the part. I really hate the original countersinks I have.  I’ll try to post a photo comparison of the different countersinks. 

Then I set up my saw horses, a large piece of plywood and a blanket as my make-shift table for the right wing. 

Its been way too long since I riveted the top skins.  The past six months have been really slow!!!! I need to be in the shop more. I used the mushroom swivel set and a tungsten bucking bar to make quick work of the rear spar.  Only a couple mistakes along the way. 

I had a previous error from dimpling the rear spar. This required a reinforcement bracket and an oops rivet, both shown below. I’m really happy with how it came out.  You can see that mistake and solution here, in the post titled Wings 17 from March of this year. 

The completed riveting job.  I’m very happy with the results. 

Next up, it was time to rivet the aileron brackets to the rear spar.  This was a pain in the ass.  It took quite a lot of force to get these rivets to buck. 

After completing the riveting for the aileron brackets, I clecoed the flap brace and aileron gap fairing in place. 

My final task for the night was to rivet the aileron gap fairing to the rear spar.  Quick work. I finished out the night with a good shop cleanup.