Brief Description: Install DuckWorks landing lights. Part 2
I have discovered the winning formula for a perfectly shaped and smooth landing light hole.
1. Small high speed cutoff wheel in a dremal tool type thing. 2. Large, medium to course sanding drum in die grinder. 3. Emery cloth that came with tool kit.
Really happy with the holes. I was a bit stressed about this task.
To cut the plexi glass I first marked the cut lies per the instructions. Put 2" low tack blue painters masking tape on both sides of the lens just inside the cut lines. This will protect it durring the shaping process. Use the band saw to rough cut, then the belt sand to perfect shape. Finally use the emery cloth to smooth out the edges. Very nice.
The third image shows the strapping tape used as a handle to pull the lens into the leading edge as far as possible for drilling the attach holes. Strapping tape is important here because it will not rip as you pull.
Oh, the kit has a four problems.
1). Section 2.9 says " Rivet nut-plates to strips, using an426D3-3.5 rivets". 3.5 length rivets for these platenuts are too long. I used 3's and got a perfect size shop head.
2). The light mounting bracket that goes between the 2 ribs is 1/4" too short. What's up with that. I'll email Duckworks about this. Very weird.
3). Section 2.10 says "DImple holes for 6-32 screws (a #30 dimple-die will work)". The 6-32 screw does not fit flush at all. It's a #6 screw so I used a #6 dimple die. The #6 screws fit perfectly flush in a #6 dimple. Why would they say to use a #30? I used a #27 drill for the hole for the #6 dimple die.
4). Section 2.4 is all screwed up. The instructions on mounting 10-32 platenuts to the ribs is all wrong. It says to drill #30 hole and use 1/8" cleco to hold the 10-32 plate-net. Will this just doesn't work. The screw hole is a #10 (3/16") and thats a lot larger then the 1/8" cleco. The 3/16" plate nut will not get centered over the 1/8" #30 hole at all. Then later it says to drill the center hole to 3/16". Will that will not work either. That is the same size as the
