Wings

These pages require the free DWF viewer from Autodesk to view some of the drawings. Free download from HERE.Right click the images for options.

 

In this photo can be seen the wing stands I use. The other end is similiar. A hole is drilled thru the pipe and into the stand through which a nail is placed. This prevents the wings from creeping with the possibility of them falling off the stands.
The outboard aileron bracket can be seen in this photo. Notice the bottom rivit is a flush head. I found there was interference between the leading edge of the aileron and the bottom round head rivit, so drilled it out and replaced with flush head.
Notice the gap between the center aileron bracket and the inside of the bracket on the aileron. This is a bit awkward since the stop for the upward aileron travel is supposed to rivit onto the side of the aileron bracket and come into contact with the moving bracket when the aileron is in the up position. This gap is there because it seems the stub rib was placed too far toward the root by about 1/4".
In this photo you can see that the bracket is lined up with the stub rib. Hindsite being 100%, I believe that if I had used flush rivits and rivited the stub rib into position, and then moved the aileron bracket closer to the end and rivited it to the spar, albeit somewhat out of line with the stub rib, that that would have been an acceptible solution.
The following images have all the necessary info to make your own landing lights. The only parts you need to buy are the lens and reflector & bulb. I bought my reflector and bulb from an offroad vehicle parts place.
Reflector mount
Side brackets. Identical but mirror images
Wing cutout. One measurement is for top, the other the bottom.
Cleco this to the two tooling holes in the ribs on either side of the cutout. This will give the correct position for the side bracket mounting holes.

The side brackets must have spacers installed under the screws to hold the brackets away from the stiffining rings around the lightning holes.

The lens goes on the inside of the wing skin. Use three flathead screws top and bottom for mounting. Fab a strip of .063 about 3/4" wide and the width of the cutout. Mount three nutplates on this strip and fasten the strip to the inside of the lens with double back tape. The screws go through the skin, the lens and into the nutplates. I ran a strip of very light weather-strip around the edge of the lens to seal out water. After the lens is mounted, I cut out to the inside dimension of the cutout, a piece of plastic headlight protector .020 thick. This is adhesive and sticks to the plexi. This makes the landing light cutout flush with the wing skin. After a few weeks/months the adhesive marks dissappear and the entire assembly becomes clear.