I trimmed the wingtip trailing edge to meet Van's specs:
Trimmed wingtip trailing edge
We then bonded the light module in place, and let it cure with the wingtip attached (to ensure it takes the correct shape, since there's a gap between the wingtip skin and the module that had to be filled):
Wing protected with mold release tape for curing the wingtip in place
Applying resin to attach light module
Wingtip light module, set in place for resin to cure
We closed up the light module by installing the inspection panel, and riveted the nutplates to the forward part:
Wingtip inspection panel installed in place
Nutplates riveted to wingtip forward edge
With the forward part screwed securely in place, we then enlarged the remaining screw holes to #28, countersunk the holes, dimped the skin, and installed the corresponding nutplates (all only on the top side, since the bottom side is attached with a hinge for better grounding):
Final-drilled wingtip attachment holes
Wingtip with attachment nutplates installed
We laid some fiber to hold the NAV antenna (Archer NAV/LOC antenna + Martin's GS extension) securely in place, and along the light module edges for reinforcement:
NAV antenna (with Martin's extension) glassed in against the inside of the wingtip
Light module with reinforcement fiber strips along its edge
I secured the aft light wires with Click Bond fasteners, as far from the NAV antenna as I could:
Rear light wires secured to Click Bond fasteners away from the antenna
I carefully lined up the static wick holes across the wingtip and aileron, and drilled those holes - the inboard wingtip holes being right on the wingtip rib:
Marking the static wick attachment holes so they're aligned
Left wingtip with drilled static wick attachment holes
I installed a nutplate on one of the holes that coincide with the rib, but left the other open for a regular nut so I can attach the grounding strap there:
Static wick attachment nutplate installed inside the wingtip rib
For inserting and removing the hinge pin, we carved out the corner of the rib and glassed in a small tube that can take the pin from a window further back on the rib to the actual hinge:
Hinge end connecting to a carefully-positioned hole on the corner of the rib, for inserting and removing the pin
Hinge pin going into the rib through a small window, and then into the hinge
I made a cover for that opening, secured the hinge pin to it and attached a couple of nutplates to secure it to the rib:
Wingtip rib cover secured in place with screws
Wingtip rib cover secured to the hinge pin
Inside view of the wingtip rib, with the cover secured to nutplates and the hinge pin, and a glassed-in tube to guide the pin
We glassed in the rib being very careful for the pin to actually slide into the hinge, and that ensured that it cured at the exact alignment needed (two attempts and a lot of cursing were necessary):
Wingtip rib secured in place, aligned with the hinge
Hinge pin and cover inserted through the wingtip rib window
With this, there's only some finishing and grounding straps left for the wingtips.
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