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Dave's RV-7A Builder's Log
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Date:  3-3-2007
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Finished landing light

Today I finished the landing light--I love the Duckworks kit and highly recommend it to anyone who is looking for a simple way to add lights. The landing light is installed in the outboard bay of the leading edge, and the process is quite simple with the leading edge off of the wing. I started the session by drilling out, deburring, and riveting nut plates on the attach brackets. After completing that task, I set about fitting the lens. Since it was a fairly cool day, I turned on the space heater and warmed up the lens to keep it from cracking during cutting and drilling. With the lens fit into the cutout, I traced the cutout on the blue tape (used to prevent scratching), then cut around it with a bandsaw. After finishing the edges on the belt sander, I used a fine sandpaper to put a nice edge on it. Once the lens was cut, it went back into the wing to be drilled. This was a multi-step process...first drilling to #40, then enlarging to #30, then finally to 5/32" to take the attach screws. After this, the lens came back out and I counter sunk the holes to accept the dimples in the skin. Finally, the lens assembly is put into place, and the lens reattached with screws. Done!
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Lens in place after drilling to #40

Lens in place after drilling to #40

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Lens brackets ready for installation

Lens brackets ready for installation

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Finished landing light

Finished landing light

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