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Date:  2-7-2008
Number of Hours:  2.00
Manual Reference:  6W6 10-12
Brief Description:  Build 2 light-channels for land/taxi lights

1. Design a light channel that is sized to mount a single AeroSun 1600 LED lght unit. The AeroSun units are 120-mm wide. See Fig. 3. I modeled the channel after the ZAC channel in 6-LLO-1. Since I'm only mounting a single light unit in each wing, I narrowed the channel and I could only fit a 65-mm lightening hole. The revised channel was made from a blank 218-mm wide by 178-mm high. See Fig. 1.The top and bottom flanges on the Zenith flange are bent backwards at 78° to mate with the nose skin. The flat end mates with the flange from the riblet, 6-WLO-1-2. (I purchased riblets from ZAC. The other end of the channel is bent forward to mate with nose rib 7. It cannot be bent backwards, because then it would be over the lightening hole in NR-7.

2. The problem is that once the top and bottom flanges are bent, they make it impossible to insert the channel into the break to bend the end flange in the opposite direction. I called ZAC and was advised to use seaming pliers for the last bend. I tried that on the right channel, but ita was hard to maintain a straight bend line. On the left channel I bent end flange ~30° in the brake before bending the top and bottom flanges in the brake. The partial bend interfered with clamping the piece in the brake to bend the top and bottom flanges, but not badly. Then I completed the bend on the end flange by clamping the piece to the table, and bending it by placing a 1x2 on the flange and hammering (gently) with a 2# sledge hammer.

The finished parts are shown in Fig. 2.

Assuming that their dimensions are OK, I believe that the imperfect bends will not be important because they don't have to bear much of a load.

I still need to put a 65-mm lightening hole in each channel.
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AeroSun 1600 LED Light

AeroSun 1600 LED Light

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