VansAirForceForums  
Home > VansAirForceForums

-POSTING RULES
-Advertise in here!
- Today's Posts | Insert Pics

Keep VAF Going
Donate methods

Point your
camera app here
to donate fast.

  #1  
Old 02-01-2016, 08:37 PM
Planecrazy232's Avatar
Planecrazy232 Planecrazy232 is offline
 
Join Date: Aug 2015
Location: Cape Coral, FL
Posts: 435
Default Team Aerodynamix Light installation

I have received so much information on this site that I wanted to give back by showing how I cut leading edge lighting into my plane.

When I bought my 6A it had a small dent in the outer portion of the right leading edge in the second bay. Hangar rash for sure from something bumping it. The plane had no nav lighting at all- so my mission was to add nav/strobes and landing/taxi lights.

After doing lots of research on what lighting to buy, (and getting sticker shock the whole time), I finally decided to go with the best I could buy- all certified LED lighting from Team Aerodynamix.

I'm not going to give a whole step by step as the very complete instructions that come with the leading edge kit do, but just what I did as far as cutting the holes in the wings.

So here is what I started with:




I cut out the templates as per the instructions and taped them in place:





Since this is a painted plane and the paint is 8 years old, I ran a heat gun into the end of the wing to warm things up before and during the cutting:



So here goes- deep breath-





continued.....
__________________
Thanks,

Anthony

RV6-A "Aluminum Mistress"
Too many hobbies- not enough time.
2016, 2017, 2018, 2019, 2020, 2021 donor and happy to do it.
Reply With Quote
  #2  
Old 02-01-2016, 08:38 PM
Planecrazy232's Avatar
Planecrazy232 Planecrazy232 is offline
 
Join Date: Aug 2015
Location: Cape Coral, FL
Posts: 435
Default

So there- I am committed now! So how to cut the section out? Well, aluminum has some of the properties of wood (so I have read). So why not a router with a wood bit?



Scary at first for sure, but the aluminum cut like butter! So smooth and controllable that I took it to within 1/8" and sometimes closer to the line. The tape shredded some, but the cut was fairly smooth.



So now to get to the finished lines and radius. Drum sander in a battery drill:



Getting there:



Complete! Came out super nice.



Next part is completing the parts to attach the lens to the wing. My next worry was doing the dimples for the lens screws. Remember my painted wing? Well I had the heat gun going this whole time. The surface was warm to the touch- not screeching hot at all. So here goes:



Perfect!! So here is the finished product. This was a challenging project, but in the end it turned out to be pretty easy. Start to finish for each side was about 3 hours.



I also used their nav/position/strobes. These are super nice lights also and man are they bright!!



Hopefully I didn't bore anyone and I hope this helps someone who is on the fence about installing these lights.
__________________
Thanks,

Anthony

RV6-A "Aluminum Mistress"
Too many hobbies- not enough time.
2016, 2017, 2018, 2019, 2020, 2021 donor and happy to do it.

Last edited by Planecrazy232 : 02-01-2016 at 08:57 PM.
Reply With Quote
  #3  
Old 02-01-2016, 08:45 PM
Infidel's Avatar
Infidel Infidel is offline
 
Join Date: Sep 2011
Location: WV22
Posts: 849
Default

You didn't bore me and thanks for sharing!
__________________
RV-4 0320\D3G 160, Whirlwind 200GA 70".
Reply With Quote
  #4  
Old 02-01-2016, 09:25 PM
wjb's Avatar
wjb wjb is offline
 
Join Date: Nov 2012
Location: Half Moon Bay, CA
Posts: 1,120
Default

Nice writeup. Yes, that DeWalt looks beaucoup scary!
__________________
Bill Bencze
N430WB RV-7 @KHAF, Flying 100+ hrs
VAF 2021 donation happily made
Reply With Quote
  #5  
Old 02-02-2016, 08:03 PM
dave4754's Avatar
dave4754 dave4754 is offline
 
Join Date: Oct 2009
Location: Edson, Alberta, Canada
Posts: 493
Default Thanks for a great picture and explanation

That was awsome and very enlightening to me as I am going to install one in m plane which may even fly this year!

Thanks again,,,,,, wondered how you ran wire to it and the gauge?
__________________
Dave Cobb
[color="Red"]=VAF=2019 Donation - and a bit extra for great work![/COLOR="blue"]
Empennage RV 7 - Tipper
Wings complete

Dynon installed and running
Fuse closer to completion, Canopy complete
AME reviewed and repaired O-320-Lyc installed
Reply With Quote
  #6  
Old 02-03-2016, 03:38 PM
Bevan Bevan is offline
 
Join Date: Sep 2007
Location: BC
Posts: 1,718
Default Speed difference

I'm wondering if there's a speed penalty since the plexi is mounted on the inside creating a forward facing bump. Since you have done this on a flying aircraft, did you measure before/after speeds or otherwise detect any difference in speed/drag?

Bevan
__________________
RV7A Flying since 2015
O-360-A1F6 (parallel valve) 180HP
Dual P-mags
Precision F.I. with AP purge valve
Vinyl Wrapped Exterior
Grand Rapids EFIS
Located in western Canada
Reply With Quote
  #7  
Old 02-03-2016, 03:52 PM
Planecrazy232's Avatar
Planecrazy232 Planecrazy232 is offline
 
Join Date: Aug 2015
Location: Cape Coral, FL
Posts: 435
Default

I'll answer two questions here. My plane had tubes installed in the wings when it was built so I just pushed my wire through them. That being said, it is easy to run poly tubing from the wingtip to the root, and fasten it in place as far as you can reach from the wingtip and bellcrank access plate, and run the tubing at the root right into the fuselage at the aileron pushrod opening.

As far as any speed reduction, I did not see any performance degradation anywhere in speed, stalls, etc. Could there be? I suppose so, but not measurable (by my butt anyway).
__________________
Thanks,

Anthony

RV6-A "Aluminum Mistress"
Too many hobbies- not enough time.
2016, 2017, 2018, 2019, 2020, 2021 donor and happy to do it.
Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -6. The time now is 11:57 PM.


The VAFForums come to you courtesy Delta Romeo, LLC. By viewing and participating in them you agree to build your plane using standardized methods and practices and to fly it safely and in accordance with the laws governing the country you are located in.