I started off the build today by checking out the fit and configuration of my newly modified wing leading edge light mounting bracket… specifically, the 3D printed mockup of it.  As I’ve highlighted before, it’s amazing what less than a 1/4″ difference makes on this build, and here on the light bracket it has made a huge difference in allowing me to both position and center the light in the wing leading edge light pocket.

To ensure I had enough clearance between the light body and the light bracket aluminum support standoffs I went ahead and mounted those to my 3D printed bracket mockup.  And as I expected, it all passed muster.

I then spent another couple hours finishing up the wing light mounting brackets’ 3/8″ diameter 6061 support standoffs by tapping and threading the 3 right wing standoffs with 10-32 threads, and then knurling the aft half and creating flox grip grooves on the lathe for all of them.  As you can see, these guys are all ready for install into the aft wall of the respective wing leading edge light pockets.

Earlier in the day I had redesigned my wing leading edge light mounting brackets’ support standoff holes drilling jigs in CAD to match the footprint of the new brackets.  I thinned them down considerably to eliminate over an hour of print time, and was able to get them both printed in under 4 hours.  And here they are, hot off the 3D printer!

Tomorrow is Christmas, so first off, Merry Christmas! everybody.  I’m not sure how much work, if any, I’ll get done but my next task is to machine the new wing light mounting brackets (which I didn’t get to today) before getting the wing lights set into position in each wing leading edge pocket.  I’ll then get the support standoffs floxed/micro’d into place.

Yes, this has been about a 2 week detour on getting these wing leading edge lights installed, but I think in the end they will add a lot of needed visibility to my bird, as well as extra light during night ops… not to mention add at least 20 knots to my ramp speed! (Smile)