I trimmed the lens a little more until it fit down inside the flange.
Instead of trying to sand the flange perfectly and then sand the lens to fit, I marked a line 5/8″ back from the face of the recess.
I’ll sand the lens back to this line and then apply filler so that the fit is perfect.
I used some scrap paper to make a template for the mounting plate. This protrudes back inside the wingtip because the mounting bracket for the light needs to be recessed behind the plane of the other face of the recess.
Here’s roughly where the light will be mounted. I’m going to fabricate this plate out of 0.040″ plate and see if that works. There’s a good chance I might have to move up to 0.063″ plate if there is too much flex. I’m going to leave the large gap around the light for now until I can fly at night and get the light aimed properly. After that, I’ll fabricate a cover plate that just clears the light to cover the hole.
I held up a piece of scrap paper where the plate will eventually cover the gap to ensure that I’m not blocking the rearmost LEDs. This position is perfect. All LEDs are visible and I have plenty of clearance from the lens for adjustability.
