Cutting holes

Hours Worked = 2.5

So now that I have my nice shiny leading edge sections built, what is the next step? Cut big gaping holes into the front of them!

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These are the rough openings for the Duckworks leading edge landing lights. I did the initial cutout with a dremel with a cutoff wheel. I left about 1/4″ or so between my rough cut and the final line. Once the initial cut was done, I put a sanding drum on the dremel and went right up to the final dimensions.

After the sanding drum, it was pretty close, but the edges of the opening were still a bit wavy, so I busted out the files and went to town. After filing everything straight, I deburred with both an edge deburring tool and a piece of scotch brite. When it was all finished, it looks like the hole had always been there!

After the main holes were finished, I began placing some nutplates that will hold the light assemble inside the wing, but ran out of time for the night.

Here are some additional pictures of the Duckworks install:

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And tonight’s featured film:

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