(Duckworks HID Landing Lights):
Its time… time to cut into our pretty skins! Now
that I have the holes for the landing lights marked, I'm ready to
open'em up! Here's a pneumatic cutoff tool I picked up from Home
Depot. Angela made me promise to practice my skills on scrap
material first... probably a good idea :-)
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The
cutoff tool works pretty good… wear a mask though… lots
of aluminum dust floating around… yuck! And be careful,
lack of attention to your 'blind-spots' could very easily make for a
bad day. Thankfully, no problems here. I used the cutoff
tool to make the straight cuts along the 4 flat sides.
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To
finish off the corners, I utilized a small cutoff wheel on the
dremel. This allowed me to get much closed to the line in the
corners.
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To
get the opening out to the line I used this cutter bit in the
dremel. This thing works pretty good and shaves away material
fairly easily. It leaves a pretty ragged edge, but the openings
are pretty much to their final size now.
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Then, to finish the landing light openings off, it was some
old fashioned elbow grease with various files, followed by numerous
passes with the small scotch-brite wheel in the drill, and then
finished off with a quick pass with a maroon scotch-brite pad.
I'm actually quite happy with the way these turned out!
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Next up is to fit the lens retaining brackets. 2 pieces
form an upper bracket, and 2 form a lower bracket. The top pieces
in this picture have rivet holes in the upper extreme corners that get
countersunk… very, very thin material to be countersinking, but
the rivets that get installed in these holes are merely used as guides
for keeping the lense in place. There's no real load put on them
since the lense will simply just slide in place between them. So
anyway, I deburred these pieces, marked them all, countersunk the
holes, and then called it a night.
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