Construction Details - Nav Lights

Whelen navlight units which incorporate both position and tail lights in a single unit will be mounted on the apex of the tip bow. The problem is that the lamp socket for the position lights ('A') extends back some distance from the mounting surface so they can't be mounted on a simple plate centered on the tip bow tube. In addition, the unit needs to be parallel to the aircraft centerline in order for the lights to show through the arcs required by the FAR's. The lights will be mounted on a metal bracket ('B')fastened to the tip bows and glued to a fairing of fiberglass reinforced styrofoam ('C').

In this photo, the first layer of foam is being glued to the inside of the tip bow. Epoxy thickened with WEST 410 structural filler was used as an adhesive. This same adhesive was used to fill the void where the square edged foam butts to the bow tube. A piece of scrap 1x6 applies even pressure to the foam. The 1" thick foam was milled to 7/8" to match the OD of the tubing on a table saw.

The first layer of foam in place and sanded.

The second layer of 2" foam will be epoxied to the tip bow and the first layer of foam.

This layer follows the shape of the tip bow only as far back as the apex. It then runs straight back parallel to the centerline of the aircraft to form a flat surface ('A') where the light fixture will mount. It then runs straight back to the tip bow at the back of the fairing.

The mounting plates are fabricated from the same 6" sheet stock used in the box tip kit. Here, one edge is being bent around a piece of 1/2" pipe clamped to the bench. When the bend springs back, it will match the radius of the 7/8" OD tip bow. Two plates are used at each tip. One inboard and one outboard. They are glued and rivited to each other and to the foam fairing.

Navlights Part 2

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