Feb 18, 2024     Tail light wire - (2 hours)       Category: Lighting

Found a way to route the tail light wire through the aft bulkheads F-711 and F-712. I used a gap in the F-711 longeron stiffener to route the wire and drilled a hole in the aft bulkhead per Dwg OP 56-2. Used pitot tubing to protect the wire from chafing on the bulkheads and also for strain relief. It was the perfect size

  Aug 16, 2023     Epoxied tail light backer - (1 hour)       Category: Lighting

Mixed up some epoxy and glued the brass backer to the inside of the bottom rudder fairing. Took a little time to get the screws lined up due to the tight quarters.

  Aug 15, 2023     Tail light installation - (3 hours)       Category: Lighting

Added a pigtail to the FlyLeds tail light using some extra 18 AWG wire I had. Pulled out the bottom rudder fairing and installed the tail light. Super tight working quarters at the aft end of the bottom rudder fairing. Had to trim the interior of the fairing to allow installation of the aluminum backer. Not sure if I need the exterior aluminum plate or not. Sent an email to Paul at FlyLeds to determine a good course of action. Tested the light with a 9 volt battery and it worked great. Big warning about not using a 12 volt battery.

  Jan 02, 2023     Tail light - (1 hour)       Category: Lighting

Ran wire for tail light

  Dec 21, 2022     Wires for left wing lights - (1 hour)       Category: Lighting

Sam pulled/cut out old bulky wires for lights that came with the wing, circa 2005, and ran new ones for “The Works” LED lights from FlyLeds.

  Nov 08, 2021     Wingtip light lens - (1 hour)       Category: Lighting

Tried to install last collimator lens into lens holder, but just wouldn't seat down far enough to engage hooks on lens holder. Emailed FlyLeds and said to return for new parts from Flyboys Accessories. All the other lens installed without a problem.

  Oct 22, 2021     Right wingtip leds - (4 hours)       Category: Lighting

Match drilled right forward facing PCB to right wingtip cove for nut plates. Installed 4 nut plates since the 5th on on top of the left wingtip was difficult to install and seemed excessive. Stripped and soldered wire ribbons that connect the two PCBs. Installed wire ribbons on outboard facing PCBs. Installed taxi/landing for fit. Installation was a PITA.

  Oct 22, 2021     FlyLeds taxi and lndg lights - (6 hours)       Category: Lighting

Started part 3 of FlyLeds build. Riveted nut plates to boards. Single leg nut plate was a PITA due to the rivets being so close together made it difficult to squeeze separately. Damaged one of the Leds. Ordered some clear glue to cover bulb per instructions. Installed heat sinks and lens covers. Installed all lens but the one damaged led. Trimmed left (red) wingtip to allow room for backside components. Drilled nut plates on fwd facing wingtip cove. Trimmed right wingtip cove for PCBs. Left a little more material than the left side.

  Oct 20, 2021     FlyLeds right tip lights and controller board - (4 hours)       Category: Lighting

Finished right side forward facing and outboard facing PCBs. Soldered all resistors and connectors to back of both boards. Installed strobe light heat sinks. Tested both boards with 9V battery to check lights and all functioned as advertised. Populated and prepped all components for the controller PCB. Soldered all components and connectors. Tested controller board indicator lights and seems to function well.

  Oct 19, 2021     FlyLeds Finished left light CBs and started right - (4 hours)       Category: Lighting

Prepped and installed left resistors and green connectors. Bent and cut leads, used a spacer to lift the resistors off the PCB for heat dissipation and soldered in place on back of PCB. Installed heat sinks opposite the strobe lights on the back side of PCBs. Soldered green connectors and tested lights with 9V battery. All worked as advertised. Began working on right ( green) lights. Trimmed PCBs to right wing tip and marked cutouts for both PCBs on wingtip cove. Prepped right strobe lights and green nav light and attached with thermal grease, being careful of orientation.

  Oct 18, 2021     Strobes and red nav Led lights - (2 hours)       Category: Lighting

Prepped more strobe light legs. Applied thermal grease to strobes and red Leds. Mounted and soldered all. Used template and cut out wing tip for forward facing lights.

  Oct 17, 2021     Wing tip lights - (2 hours)       Category: Lighting

Used FlyLeds template to make make cutouts for both the forward facing and outboard facing circuit boards. Trimmed the forward facing circuit board circuit board to fit the left wingtip light cove. Also beveled the aft edge of the outboard facing PCB to sit flush against the forward facing PCB.

  Oct 16, 2021     Wing tip lights - (2 hours)       Category: Lighting

Trimmed outboard facing circuit board to match wingtip light cove. Began prepping LEDs for solder installation and cut out template for wing tip trimming.