24 – Wing Tips Part 3 – Nav Light Covers

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I initially struggled to find a way to cut the nav light covers.

But then I spotted my tin snips, which had been included in my initial tool order from Cleaveland, but which I hadn’t used at all …


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… until now!

They proved to be ideal for acurately trimming the covers.

I masked the covers to prevent scratches.


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Fitting was another iterative process, gradually trimming and sanding the covers to match the wing tip recesses.

I found that the AeroLED moldings needed some fettling to allow the covers to sit snuggly.

The original Vans profiles in the wing tips are much closer to the required shape.


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Once I was happy with the fit, I drilled the holes for the attachment screws …


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… and then used the usual temporary bolt to secure a nutplate for match drilling.


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Careful use of the rivet gun was needed to set the rivets.


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The manual asks you to final drill the holes in the nav light to #28. I didn’t have such a drill size, but having reamed the hole to #30 …


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… I found that it allowed the #6 countersink bit pilot to fit just fine in the acetate.


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I wasn’t happy with the recess lip in the molding for the covers … it varied too much in depth, leaving portions of the cover proud of the surface.

I decided to produce my own recesses to match the covers.

After masking the cover edges with parcel tape to act as a release agent …


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… I applied microballoons along the cover edges.

It was lots more work, but after the usual filling/sanding …


… I ended up with a much better fit.

If I hadn’t done this I know that every time I walked up to the wingtips the bad fit would have offended me!

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