Tag Archives: lights

Rudder Anti-collision light wiring

Hours: 2

Now that the Rudder is almost complete, I needed to make the wiring for the Anti-collision light permanent. The existing wire of the Aveo Posistrobe Minimax I’m using has 4 wires (ground, power, strobe, sync), so I needed to splice those onto the wire so I could run it through the structure.

Since this is a permanent connection, I’m using Heat Shrink Solder Sleeves, which have solder in the center and when you heat it up, the solder melts and the sleeve shrinks down to create a good seal.

After that was done, I added some expandable braided Sleeving over the wire for extra protection.
Expandable Braided Sleeving for the wire

I up sized the hole for the wire to pass through the fiberglass tip using my step drill bits and then ran the wires through the structure and out the front hole, which I also had to drill up as per the instructions. After some more research, I replaced the rubber grommets with snap bushings. They last longer and for the front hole in particular, they hold on better since they snap in place.
Finalized hole size for the wiring to pass through the fiberglass tip Snap bushing for the wire to come out of instead of using rubber grommets

Here’s the light mounted and completed wiring done.Light mounted and wiring finished

Now the last thing to do is close up the top. Inspired by a discussion from a while ago on the Sling Builders group, I was contemplating the idea of making the fiberglass tip removable using nut plates and screws, but I think I’ll end up just riveting it closed.

 

Rudder structure riveting

Hours: 1.5

Now that I’ve prepared the Rudder parts with primer for the mating surfaces, it’s time for more riveting. I laid out all the parts and got to work assembling the Rudder structure.

Rudder parts ready for riveting Fitting the ribs of the Rudder

The strengthening plate is thicker and needed a bit more attention to deburr both the big center hole using my straight double edge deburr tool as well as the riveting holes. Most of the other holes were prepped well by the factory after checking them by running my finger over them.
The strengthening rib needed a bit of deburring

After everything looked good, I finished putting together the structure of the spar and all the ribs and lined up everything with lots of clecos.
Rudder structure laid out for riveting

And then it was time for another episode of riveting.
Riveting action Completed the riveting of the structure of the Rudder

I still have to buy the tail anti collision light that will go on top of the Rudder. I’m planning to get the Aveo Posistrobe MiniMax and then I’ll finish up putting on the skin.
Since I am planning on installing a VOR/LOC/GS antenna, I will run the wire for both the antenna, as well as the strobe light in one go through the Vertical Stabilizer as the instructions suggest.