Now I understand when people say they are hesitant to cut open a good wing skin. Using the templates, I marked the skin for cutting and marked nut plate locations on the outer two ribs. Those two ribs hold the light mounting bracket and its design allows adjustment of the mounthing bracket to shine the light in the right spot on the runway. The HID D1S bulbs are the best you can get. The power pack was too bulky to fit on the mounting bracket so I located it on the rib and mounted it using 10/32 nutplates and AD3-4 bolts. Washers on each bolt between the rib and the power pack raised it enough to run zip ties under it to help secure the wiring. Of course, I had to try out the light and it was very white and very bright. After alll three hours of fiddling with the lens, cutting it on the bandsaw, pulling it up tight to the opening to match drill 6 mounting holes, countersinking the lexan holes to accept the dimples I put into the wing skins, I discovered the two lexan sheets supplied by Duckworks in the package are different thicknesses. I inadvertently used the thinner one thinking that was the correct thickness. What it was was a practice sheet. Good thing because I cracked it near one of the mounting holes when I tightened it up with the screws. Now, I will remake the lens with the thick lexan piece and am comfortable knowing what has to be done. I should have noticed the two different thicknesses, but I didn't. No big deal. Just more work. When I prime the flaps and ailerons, I will white prime the duckwork mounting aluminum too.
I can't believe I did this to a good wing skin....
Power Pack wouldn't fit on lens mount so it went on rib.
