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Zenith CruZer & Sonex Logs
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Date: 8-17-2011
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Number of Hours: 3.00
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Manual Reference: n/a
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Brief Description: Trial fit strobe / nav / position light pods
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Started fitting the strobe / nav / pos light pods onto the wingtips.
First up was a decision on how to mount to allow access in the future. I am going to mount the wingtips to the wing using aluminum rivets allowing easy removal if needed. Of concern was how much "meat" would be left on the wingtop to allow solid mounting yet allow easy access to the back of the units for un-mounting the units, replacing strobe bulbs, etc. Since I am going to permanently mount the pods to the wingtips using 3M marine adhesive (strong stuff!), removing the pods will not be an option.
Once I determined that I could cut access holes in the wingtips yet still allow sufficient room for the adhesive, I positioned the light units on the pods, marked the holes, and drilled.
I then had to file the backs of the pod units as there was still some molding edges present that would have prevented a flush fit onto the wingtip.
Next, I had to decide where I wanted the pods mounted on the wingtips. I've seen several completed birds that have the light units at an angle that looks good on the ground, but that would obviously not be parallel with the horizon in flight.
To help this out, I marked the chord line on the wingtips and positioned the pod (with light) to where it looked "right". Picture 2 below shows the result. It looks "off", but remember that the tip is at a 45 deg angle when in place on the wing.
Lastly, I cut the access holes in the wingtips for access purposes. With the pod in place, I have access to the strobe bulb as well as the mounting bolts for the light unit to the pods.
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holes drilled for mounting & wires
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chord line & positioning pod
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Acess hole cut out
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