SECTION OP-52: LANDING LIGHT

Build Instruction Updates

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Before You Start

Special/New Tools/Supplies

• You need #27 and #30 plexi-bits for this section.
• You need a way to cut into the leading edge of the wing -- consider using some combination of: jigsaw, oscillating tool, cutoff wheel, Dremel tool.
• You need some double-sided tape (the plans recommend 3M Transfer Tape F9460PC VHB)
• The plans suggest you may want to paint the inside of the cutout with either gloss white or matte black paint. Also, consider painting the back side (where the nutplates are installed) of the W-00018 brackets since you can see them after installation.

Modifications to Consider

• Decide if you want to mount your light directly on the bracket or install a bracket to allow the light to be tilted up and down. You can use W-00016B from Van's for this purpose. See this discussion on VAF.

OP52-03/05 Template Pages

• The drawings are not printed at 1:1 scale, see this FB Post.
• Note that as of Jan 2026 this free tool can quickly and easily split each page of the OP-52 PDF into two 8.5x11 pages that you can then print without scaling on your normal printer.

Hints

Page OP52-01

• Step 13: Consider painting the inside of the wing as described, but also the backs of the W-00018 backing plates (possibly after installing the nutplates) and the W-00017 mount brackets, or at least the front and sides. This will all be at least somewhat visible after installation is complete.

Page OP52-02

• Step 4: It may be tempting to really clean up the edges at this point, but note that cracking can be very common during the drilling and countersinking in steps 5 and 7 later on this page. Consider final-drilling the holes and completing the countersinking and deburring before spending any time on the edges of the lens. If the lens cracks you will have wasted less time.

• Step 5: When match-drilling, it's very easy for the plexiglass to bend away from the skin and causing the hole to shift while drilling. This will make the lens not fit tight against the opening. Consider either supporting the lens very well from the inside while drilling OR placing the lens, marking the hole, removing the lens, drilling the hole, replacing the lens (plus a cleco in the new hole), marking the next hole, removing the lens, drilling the hole, etc, etc.

NOTE: it's easy to crack plexiglass even while drilling with a plex-bit. Consider drilling slow with minimal pressure, and make sure the plexiglass is warm or hot before drilling

• Step 7: Again, it's easy to crack the holes, so drill soft and slow.

• Step 8: Consider a series of sanding steps on the edges of the lens. Start with 100-200-grit to remove any visible cut lines, then work up to 300-400 grit and finally 800-1200 grit to really make the edges smooth. Consider using a tool or sandpaper to radius the inner and outer edges.