I set out to tackle the landing light installation. Since the SuperSTOL doesn't have an OEM solution to landing lights, I had to adapt my own.
My first idea was to mount the AeroLED MicroSun bracket to the underside of the leading edge skin in a similar fashion as Trent did on his Kitfox.
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| Trent Palmer's Kitfox |
This would require riveting and Hysoling a plate doubler in to provide a more secure mount for the bracket. After thinking about this option for a few days, I realized that the LED's would sit high and close to the skin but would be partially blocked when the slats were deployed. Although this mounting would provide a reasonably aerodynamic solution it wouldn't work in my application because of the slats. So, decided to go in a different direction.
I decided on trying to mount them to the wing struts in a similar fashion as Paul did on his SuperSTOL XL.
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| Paul Zimmerman's SuperSTOL XL |
However this position presents several problems. First, it definitely creates more drag. Second the airfoil shape of the struts creates mounting issues. Third, the
struts angle backwards toward the fuselage creating an aiming problem. The good news is that the slats would not affect them.
I started by cutting some .020" aluminum strips that I hand formed around the strut.
I then made some bends in the ends to create tabs. Then using the AN970-3 large washers, I drilled bolt holes in the tabs.
Initially, I wanted to mount the LED's level with the wings. I could not think of a way to do so that was easy or didn't involve designing a 3D part and using a CNC to cut it out. My first attempts were not functional.
So, I quickly abandoned that idea. Once I attached the LED bracket and the light, I realized the .020" aluminum I used was too thin and flimsy.
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| Small pile of rejects |
So, I moved up to .032" aluminum. This proved to be stiff enough while still allowing hand forming. I then began trying to make the brackets equal in shape.
Once I attached the bracket and the LED the aiming issue came to light. The solution was to staggering the tabs on the brackets (one towards the front of the strut, the other toward the back) which canted the LED bracket thereby adjusting the aiming point of the LED in a more forward position.
After several attempts I finally ended up with brackets that mirror each other, are strong and hold the LED's in the correct position to clear the slats and aim at the correct point forward.
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| More rejects |
