I fabricated .063 2024-T3 doublers to mount the Aeroflash Nav/Strobe lights with the same dimensions as the base of the units. Only two front screw holes were usable on the Aeroflash units, so I drilled an additional aft screw hole for greater fastening security. I attached the doublers provisionally using sheet metal screws to the wingtips at the wingtips widest point (slighly aft of the front spar), and used a plumb line with the tips installed on the aircraft to make the doublers perpendicular to the ground. I then caulked the edges with RTV in order to have both a base for the doublers as well as provide a backstop for the fiberglass, and allowed the RTV to dry. I then trimmed the RTV and drilled the holes. I then epoxied two ply's of fiberglass and allowed that to harden. I then sanded the edges of the fiberglass smooth, and then followed 4 iterations of microballooning/sanding I also fabricated nutplated backing plates which will be glassed into place on the inside of the wingtips, and they will be seen in the Nav Light Fixture Wiring log.
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