Ground down pulled rivet heads so lens cover would fit. Drilled holes in mirrored plexi and fiberglass tip to use nylon bolts to attached the LED light assy, instead of epoxying. Final fitting of assy into wing tip...cut-fit-remove cycle.
What would I do differently? The LED lights have consumed a lot of time and I still doubt the overall result (use of epoxy, lots of cut holes, etc). Far easier to simply use a conventional Grimes Nav/Strobe light assy. I might do this again but with more thought into how to attach the LEDs to the plexi, and the plexi to the fiberglass. The original in VAF had a single Al backing/heatsink for the LEDs...which unfortunately goes against the clear instructions by the LED manufacturer that these LEDs should not have their bases electrically connected. Perhaps two larger Al plates or something...
