March 2, 2008 - Wingtip Light Covers

I drilled the mounting holes for the nav/strobe light in the left wingtip.
 
Fits nice.
 
Now for the clear pexiglass covers.  The kit came with a single piece that you have to cut in half.  First I had to wash it off; it literally had three and a half years of dust on it.  The Dremel tool and heavy duty cutting disk did a nice job cutting it. 
 
I cut the bottom flange off first. 
 
As you can see, the aft edge still overhangs quite a bit.
 
So my next step was to cut that off.
 
Now the bottom edge overhangs.  What I ended up doing was getting the forward and top corners right, then getting the aft edge right, then finally the bottom edge.  There was a lot of back and forth -- trim and fit, trim and fit.  I used the vixen file and sanding block 60 grit to trim it down; later I used the sanding disk on the Dremel.
 
But I finally the fit to where I wanted it.  Then I sanded it smooth with 150, 220 & 320.
 

The second cover went just like the first. 

Later, I drilled the nutplates holes and Lynnette helped me rivet the nutplates in. 

 
I've been thinking about doing a little aluminum polishing while I wait for spring to come.  I broke open the Nuvite polishing kit I had bought last year at Oshkosh. 
 
I peeled the blue plastic off the left flap.  I might start with the flap. 
 
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