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Saturday, April 2, 2016

4 hrs. finishing the light mounting plate, installing the tip light assembly and the wing tip to the wing.

Following the instructions for placement of the light.

First hole to be drilled is the mounting hole.

Broader view.  This is the bottom of the tip.

The hole is drilled and the M5 size rivnut fits.

I noticed on the inside that a piece of fiberglass sheet is crinkled up where the plate has to go.  That has to be removed.

Locating the rivet holes.

One down and one to go.  Started by drilling small pilot holes and then used chucking reamer bit to enlarge the holes to size.

Double checking with the rubber gasket.

And everything is lining up.

Cut out the bubble with an Exacto knife and then sanded it down (after the photo).

The wires fit through.

Outside looks good.

And so does the inside.  The rivnut and rivets have already been installed at this point.

Checking the wiring one last time...

Looking good!

And the tip is riveted on!!  I'm holding the light in place because I'm waiting for the M5 sized mounting screws (45mm long) to arrive.  Hopefully later this week...

And it really looks like a wing!

NEXT TASKS:
  1. Rivet the one on the step rib that needs special handling.  OK, I've been putting this off..
  2. Composite filler for join between wing tip and skins. Perhaps other seams can use some filler?
  3. Put the aileron and flap on the wing to check for straightness of the trailing edge (Thanks Peter, I saw that on your blog! ;-)). Based on what I'm reading online it seems likely that I'll need to re-rivet some of the aileron/flaps to line up the trailing edges...  Wish I knew this before I had riveted them...
  4. Mount light when the screws arrive.
  5. Finish right wing.
  6. Finally finish one of the composite tips of the elevator.
  7. Fill rivets of elevator with Bondo.
  8. START ON FUSELAGE!

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