Connecting Wing Wiring

April 27, 2021 – Now that the wings are on I can connect the wing wiring.

I safetied the tank attach bolts. Not sure why they need to be safetied, since they go into a nutplate that locks, but OK… I drilled the safety wire hole in the steel bracket.

I also installed the fuel lines.

I ran the pitot and AOA tubes into the fuselage and back to the ADAHRS, then connected the heat controller. Put power on the airplane and the heat works. I don’t have a message saying the heta is either on or off yet; I’ll set that up later in Dynon.

I ran and terminated the wires for the roll autopilot servo. The Skyview network portion is connected to the hub in the back.

I plan on connecting the wires for the lighting and the stick grips on a terminal bar under the left seat.

When I tried my lights, I had crossed the wires for the right landing light and the right nav lights. Got that figured out and now the lighting works correctly.

Time: 25:00

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Right wingtip complete

October 23, 2013 – With the right wing on the table, I wanted to arrange the wiring so that the wingtip would be removable and the wiring would be reasonably secured.

I cut the 4-strand cable for the strobe to length and terminated the wires for the wingtip. I clamped the wires to the rib I installed in the tip. Here’s a before and after:

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Here’s close-ups of the wiring inside the tip, and of the terminal connection on the wing itself.

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I temporarily installed the wingtip to the wing, mainly just for storage. The phillips head 4-40 screws I have will not work later on. I’ve already stripped a few of them, so I’ll be getting torx fasteners later on.

Of course I had to try my lights with everything installed.

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I’m calling the right wingtip complete.

A friend from work came over and helped me put the right wing back in the stand and the left wing on the table.

Time: 2:30

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Started wingtip lenses

March 21, 2013 – I started cutting and fitting the wingtip lenses.

Van’s provides you with a formed bubble of plexiglass that you cut to make the two wingtip light lenses. I didn’t get a picture of it before I cut it in half, but here is a lens half before trimming:

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I set it in place over the wingtip cutout and started trimming. I was able to use snips until I was down to fine adjustment, when I used files and sandpaper.

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When I was happy with the fit, I taped it in place, and drilled the screw holes at #40, and clecoed the lens in place. Now on to the other one…

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Time: 2:00

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Wingtip lighting almost done

March 5, 2013 – I’ve come a long way since my last update.

Since I did the green LEDs last time, I got the red ones done:

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Here’s a guide to how I wired the LEDs:

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I installed the strobes on the wingtip cutout backing plates I made. As I wrote before, I didn’t want to attach the strobes to the wingtip fiberglass.

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These are the outside and inside views of the strobes. The strobes are Whelen Vertex Hide-a-way Super LED strobes that I got from Strobes N’ More. If they turn out to be not what I need, the cutouts are the standard 1″ hole, so I can drop in a regular strobe if required.

030513005The next thing I needed to do was to make spacers for the screws for the mirrored plexiglass since it sits on top of the LEDs. I needed 1/4″ OD and ID to fit a #6 screw. I found longer spacers and cut them to fit. Unfortunately, the height I need is only 1/8″, so these were kind of a pain to make. They aren’t pristine parts, so I’ll be replacing them with better spacers at some point. For now, they do the job.

Here you see the spacer between the rivets for a nutplate:

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…and placed over a screw for the plexiglass:

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Here are side views of the plexiglass installed with the spacers:

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I hooked up both wingtips to power, and…

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…everything works!

Not the best quality, but you get the idea…

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I started installing the wiring on the outboard wing ribs. I made brackets for the LED drivers. I used thermal epoxy to attach the driver pucks to the brackets, then screwed the brackets to the ribs. I plan on using the terminal bars to connect the lighting to the wiring, so I installed terminals on the driver puck wires.

Time: 6:40

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Started work on wingtip lighting

January 11, 2012 – I had some time to tinker, so I took down a wingtip from its storage, and I made the template for the LED lighting for the position lights. I’m using the system done by David LaSala. Just barely got started with this, because due to the lack of funds for the fuselage, I want to do this work after the wings are closed.

Here’s the template I traced from the outline of the cutout for the tip.

Time: :20

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