Wingtips and Lights

Wingtips

In this episode, I install the VOR antennas and position/strobe lights into the wingtips. I also install the 5,120,121 nutplates required to hold the wingtips to the wing, and then install the lenses that cover the cutouts for the lights. I'm using the Archer antennas, which are very clever designs that seem to work even when the VOR station is on the far side of the airplane. The nav/strobe lights are AeroLEDs NS90s. They use LEDs for both position (i.e. red/green) and strobe (i.e. flashing white) lights. They have a DC-DC converter built in, and it does generate a bit of noise, but not as much as my attempt at roll-your-own LED lights using Nova strobes. Aside from the lower power draw, I'm happy to not have to worry about ever replacing bulbs. I also don't want to have a high-voltage power supply as required by xenon strobes.

First I glassed in the Archer antenna. The inboard edge (closest to you in the photo) is held in by the same rivets that hold the nutplates. That edge is supposed to be grounded to the metal wing skin.

First I screw a #6 screw into the nutplate (or whatever the appropriate size is) from underneath. It only needs to be finger tight.

Then, I drill the first 3/32" hole for a rivet. If I really care about alignment, edge distance, etc. I use a cleco side-clamp to hold the nutplate while I'm drilling.

Then I stick a cleco into that hole, and drill the other hole.

I just keep going like that until they're all drilled. A row of N nutplates requires 3N holes...so it's a PITA.

Then the holes have to be countersunk. More of a PITA.

But even the darkest nights eventually end, and here are all my nutplates riveted and countersunk.

Now the antenna is attached by fiberglass, rivets, and three screws through the wingtip layup holdin those cable clamps. I also installed the coax pigtail that connects the antenna to the long coax in the wing. The Archer instructions tell you how to route the wires from the light to avoid distorting the antenna pattern.

This wingtip is almost done. The nav/strobe light is installed, the wires are routed to the wing, the antenna is installed, and the nutplates are done. Those tie wrap anchors are glued into position...I have not been able to make the self-adhesive anchors work on any surface.

The Van's instructions are a bit vague on how to attach the lens to the cutout. I probably went overboard...but I was in the throes of a nutplate-installing frenzy. Some guys use just one screw, in the corner, and that seemed a bit under-done to me.

One of the advantages of living in a house with two young girls is that there are plenty of braiding experts. The AeroLEDs lights have ground/position power/strobe power/sync wires. The sync wire allows all the strobes to flash together.

Done! And yes, I used different attachment schemes for the two sides...we'll see which one cracks first.

Even with the basement lights on, you can see these things in the photo. My wings essentially look like long DB-9 and coax extension cords, electrically, so I can plug the wingtips directly into the fuselage for test purposes. Thus I know that the lights work, but also that the switches and wiring work.

First I glassed in the Archer antenna. The inboard edge (closest to you in the photo) is held in by the same rivets that hold the nutplates. That edge is supposed to be grounded to the metal wing skin.	First I screw a #6 screw into the nutplate (or whatever the appropriate size is) from underneath. It only needs to be finger tight.
Then, I drill the first 3/32" hole for a rivet. If I really care about alignment, edge distance, etc. I use a cleco side-clamp to hold the nutplate while I'm drilling.	Then I stick a cleco into that hole, and drill the other hole.
I just keep going like that until they're all drilled. A row of N nutplates requires 3N holes...so it's a PITA.	Then the holes have to be countersunk. More of a PITA.
But even the darkest nights eventually end, and here are all my nutplates riveted and countersunk.	Now the antenna is attached by fiberglass, rivets, and three screws through the wingtip layup holdin those cable clamps. I also installed the coax pigtail that connects the antenna to the long coax in the wing. The Archer instructions tell you how to route the wires from the light to avoid distorting the antenna pattern.
This wingtip is almost done. The nav/strobe light is installed, the wires are routed to the wing, the antenna is installed, and the nutplates are done. Those tie wrap anchors are glued into position...I have not been able to make the self-adhesive anchors work on any surface.
The Van's instructions are a bit vague on how to attach the lens to the cutout. I probably went overboard...but I was in the throes of a nutplate-installing frenzy. Some guys use just one screw, in the corner, and that seemed a bit under-done to me.	One of the advantages of living in a house with two young girls is that there are plenty of braiding experts. The AeroLEDs lights have ground/position power/strobe power/sync wires. The sync wire allows all the strobes to flash together.
Done! And yes, I used different attachment schemes for the two sides...we'll see which one cracks first.
Even with the basement lights on, you can see these things in the photo. My wings essentially look like long DB-9 and coax extension cords, electrically, so I can plug the wingtips directly into the fuselage for test purposes. Thus I know that the lights work, but also that the switches and wiring work.