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Date:  9-22-2007
Number of Hours:  14.50
Manual Reference:  Duckworks Manual
Brief Description:  Installed leading edge landing light

Here's where I took a very deep breath and cut into a perfectly good wing...Ductwoks has some pretty good instructions (until you get to the very last item. I had to cut out some cardboard templates and adjust the to so the cutout was 18 3/4 inches from the leading top-skin seam and 2 1/2 inches from the nearest inboard rib. I drilled four quarter inch holes in the four corners of the cutout and then used a jig saw with a metal cutting blade to make the cutout. Then I used a scotchbrite wheel to clean up the edges. Next I had to mount the inside brackets and cut the lens to fit. I used my band saw to cut the lens and that worked very well. I followed Duckworks instructions and when I got to the part where they said, " use your deburring tool to make the lens attaching screw dimples" I thought that was stupid, but did it anyway. Well guess what...THAT WAS STUPID! When I screwed the mounting screws tight, they poped right through the skin. It was extremely difficult getting everything apart with the popped screw...not a lot of room to get the lens out. Anyway after 2 hours of messing around with the lens I talked to my tech advisor and I installed bigger nutplates and screws. This time I used my dimpling dye and it worked just like the other 10,000 dimples I've done. I've found several of these mom and pop instruction manuals have really dumb things in them. My advice is if you've gotten this far trust your own skills and judgement when it comes to sheet metal work.

In the end, the light istallation looks just fine.
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Cutout made and brackets installed

Cutout made and brackets installed

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Drilling the Lens after it was cut

Drilling the Lens after it was cut

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Finished installation

Finished installation

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