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Zenith CruZer & Sonex Logs
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Date: 1-29-2009
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Number of Hours: 1.50
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Manual Reference: n/a
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Brief Description: Install Light Kit Lens Brackets
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Decided to go with the flush, driven rivets that Duckworks supplies for mounting the brackets which secure the landing light lens in place. My neighbor / CFI, who is also building an RV-12, had a rivet squeezer, so he came down to help (Thanks, John!).
Positioned the upper bracket piece, drilled holes for the rivets. Assembled the two parts of the bracket, riveted them together, bent the "lip" part as per directions to aid in the lens fitment, then riveted the bracket in place.
Flipped the wing over to work on the lower bracket. This one is assembled and riveted with nutplates, which are used to screw the lower lens retention bracket into the lower skin, allowing easy removal and access (for things like burned-out bulbs?). Positioned and drilled the locating holes as per directions, then riveted the two halves of the bracket together using flush rivets and the nutplates.
Dimpled the screw holes using the Sonex Super Simple Dimple Die, but the screws did not fit as flush as desired. Duckworks recommends using a #6 screw die for dimpling, and fortunately John had a #6 die. Once we re-dimpled, the screws *really* fit much better - if you're going to install a Duckworks light, find a #6 die to borrow for those 3 screw holes. Big difference!
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Flush-Riveted Upper Bracket
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Overall shot; Dimpled Lower Bracket Holes Visible
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