I started out today pulling the peel ply, razor trimming the overhanging carbon fiber and cleaning up the edges of the left wing leading edge light lower flange.  This completes the construction of the left wing leading edge light compartment with only the actual light & bracket install along with running the electrical wire cable left to do (ok, and attaching the lens at some point down the road).

On the right wing leading edge light pocket, I pulled the peel ply off of the 2-ply BID layup and cleaned up the remaining peel ply boogers.

Then, as I did on the left wing light flange, I taped it up with green tape to make the marked cut line more visible (pic 1) before I trimmed off the excess flange, making it 1/2″ wide all the way around (pic 2).

I then removed the tape and the clecos to take a look… not bad!

I test-fitted the lens, which took a little bit of sanding down the bottom edge and outboard corner to get it dialed in and fitting snugly.  There are still some slight gaps around the perimeter that I will most likely fill in with micro.

Also, as I did on the left side, I laid up a single ply of carbon fiber on the floor of the light pocket, overlapping the bottom perimeter edge of the flange and continuing about half way up the inside leading edge of the flange.  I then peel plied the layup and left it to cure overnight.

With my final layup done on the right wing leading edge light compartment, I then tried out my 3D printed wing light mount drilling jig inside the left wing light pocket.  It was then I realized —which may not be overly obvious or visible in the pic below— that the outboard corners of the jig were preventing me from centering the jig in relation to the light opening in the flange.

As a certified Neanderthal airplane builder (that’s not really a thing…) I simply grabbed my belt sander and trimmed down the outboard corners of my 3D printed jig.  While the smell of burnt plastic wasn’t the greatest, it did do the trick.

And now the light mount support drilling jig fits inside the left wing light pocket… I still have to do this (most likely) on the right wing light mount support drilling jig as well.

And here’s a clearer pic without my ham-fisted hand in the way… my plan is to work on the 3 light mount standoffs (per wing) on the lathe to get them cleaned up and tapped with 10-32 threads for install.

My guess is that as Christmas draws nearer, my build time in the shop will both be shorter and more sporadic.  In addition, Jess and I are heading to Ashville for a few days over New Years, so clearly no airplane building —at least physically… it’s always going on in my head!  Hoo-ah!