Wing Tip Lenses Take 2

Time: 6 Hours

Ok it’s been a while since my last post. Life sometimes gets in the way and that’s ok especially since my available project items are dwindling down as I wait for an engine purchase. I have been excited to get back in the shop and get back to building. The process of adjusting and cutting the lens to shape and sanding to final fit was the same as the last post. 

Once I got them to a very close final fit I drilled for two screws, one on the top and one on the bottom, so that I could ensure they return to the same spot as I removed for sanding. 

Once I had the fit perfect I worked on the nutplates for the screws. I tried blind riveting the nutplates in place with countersunk blind rivets. I just wasn’t happy with how they were fitting so I turned to another idea. I just clecoed the nutplates in place and covered them with epoxy/flox which cures extremely strong. After they cured I countersunk the lens for a #6 screw and put them in place. 

The fit was great and the flox worked perfectly. I had to careful with the nutplate placement so they didn’t interfere with the landing light attach points. I then removed the lenses and filled the drillled holes from the blind rivets with Super Fill. 

I will sand those areas down and reprime the tips to find any pin holes. After that I’ll reinstall the lights, lenses and tips back on the wings for storage.