|LED nav lights with integrated landing light:|
I purchased a set of LED navigation lights from http://www.killacycle.com. I had this idea of putting the landing lights in the wing tip, so I purchased the style with the hole in the middle for the landing light. I didn't purchase the landing light option. I felt they were too expensive. Instead, I set out to design my own landing light to attach to the navigation lights. I started with a set of PIAA driving lights. This particular set has a long, focused beam and a very compact housing. I used .063" thick 2024 aluminum sheet and some hardware store 1/2" x 3/4" aluminum angle to fabricate the parts for the adjustable landing light brackets and reflector. I purchased all the hardware at my local Ace Hardware store.
I used two long bolts that are 10-32 x 1 1/4" stainless socket heads and the one short bolt is the same except 1" long, three thin nylon washers and three .1" nylon washers and one miscellaneous spring the just fits over the screws and has enough tension to support the landing light assembly.
I didn't separate the regulator portion of the LED board from the lamp portion in the hopes that this would give the system less solder joints to fail.
The assembly goes together like this; First the navigation lamp board slides into the slot regulator end first.
The screws are pushed through the board, then through the .1" thick nylon washers. The screws then go through the wingtip fiberglass and are held in position by the thin nylon washers (fig 1). These actually end up as the support for the springs that keep the landing light in place.
Figures 2 and 3 show the lamp assembled to the fabricated brackets. I cut the small spring into three 3/4" pieces and slid them onto the screws. Figure 4 shows how the lamp assembly is attached to the adjusting screws and held securely by the spring tension. The self locking nut-plates were slightly modified to allow more angular displacement for the light beam adjusting process. To do this, I placed each nut-plate in a vise and used a small, flat-bladed screwdriver to pry open the tabs that hold the nut to the plate. The tabs only need to be opened about an additional 1/16" to 3/32" to gain enough angle for full adjustment. If the nut can fall out of the plate, the tabs need to be closed down slightly. The holes in the attach brackets are enlarged to 1/4" to allow the angular movement of the screw during adjusting. Be sure to drill the nut-plate rivet holes before enlarging the screw hole.
_Fig_1 _Fig_2 _Fig_3 _Fig_4
The last photo is a bit blurry, but shows how the assembly looks fully installed. Note the aluminum plate I fabricated to reflect light to the side. This will be polished before final assembly.
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