Landing Light 1
If you plan on installing landing lights in the leading edge, the best time to do it is with the assembly riveted together (and off the wing). I chose the Duckworks kit (as many others have). It is an extremely thorough kit, and I was impressed with the overall quality.
1st step is to disassemble the light housing. You will only use the reflector and bulb and throw away the rest. I originally bought the 55W version, but I replaced it with 100W bulbs from Autozone ($6 each). Duckworks sells the lights in the 100W size, but the cost is more than $6 more.
Next comes time to locate the template on the leading edge per the plans. It gives dimensions to the edge of the skin, so it is pretty easy to locate. After the template is in place and a line is traced, it is time to cut away. I used a three step process to make the cuts:
Cut majority of area away with 3" cut-off wheel in die grinder
Finish the area of the hole so that it is approximately the right size and shape with a sanding drum in the dremel
Use a half-round file to do the fine finishing and get a perfect shape.
It does take some time to do, but the end result is a very nice cutout.
Next comes time to locate the mounting bracket attach nutplates on the ribs. The instructions I had referred to three sets of holes (A, B, and C), but the template only had locations for two. I contacted Duckworks, and they confirmed that the "C" hole was used on older kits (but is no longer used). He also said that I would be able to aim the lights for taxi if only the two holes were used.
That being said, another template was used to locate the screw holes in the rib. I then used my handy nutplate jig to finish the rivet holes for the nutplates. The plans say for blind or solid rivets here...since they really won't be doing anything (other than prevent rotation), I went ahead and put the blinds in.
