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Submitted By:		jhstarn@earthlink.net
Email List:		RV-List,RV3-List,RV4-List,RV6-List,RV7-List,RV8-List,RV9-List,RV10-List
Name:		John Starn
Date:		Jun 28 2003
Subject:		Wing Tip Storage Lockers
Description:		Your wing tip lights may vary. We installed an end cap of 'glass to seal off the light area. Made a flat section of glass on wax paper then cut it to size and glassed it in. Photo came out fuzzy, too close. If you have any questions, ask. Sorry it took so long. Hope I got everything you might need. KABONG
		Photo01.jpg	Left wing of HRII N561FS. Door is located on the "flat" section of the wing tip, aft of the main spar. Nav. lights are shown as installed in the front & tip edge of the wing tip.
		Photo02.jpg	View from the rear of left wing. Four (4) camloc's shown as round heads in the corners and at the mid point of the door. Door is attached to forward edge with piano hinge.
		Photo03.jpg	Left tip door in the open position. Shows the rolled edge angle used to reduce flex. Angle is held in place by placing fiberglass over the entire angle surface. Hard to see but there is a .040 shim between the exposed half of the angle and the door itself. Shim required to keep the hinge down flat and keeping the door flush with tip surface.
		Photo04.jpg	The "shim" indicated in photo #2 is the bright ring of aluminum shown under the hinge. The interior half of the hinge is the "lowest" of the hinge/support ring/wing tip fiberglass sandwich. Half of the gray support ring can be seen inside of the open fiberglass hole. The door is 12"X8", the support ring is one piece .040, 9 1/2" X 14" OD & 7" X 11 1/2" ID. The lip the door rests on is 1/2" wide on the three sides that are visible, 1 1/4" wide where the hinge attaches and 3/4" wide on the three sides under the fiberglass where rivets are attached.
		Photo05.jpg	This shot more clearly show the .040 shim between the hinge and the door. The hidden half of the hinge is cut to fit (some eyes removed) and is the full 14" wide (same as the OD of the support ring). NOTE: The holes for the center camloc's have VERY thin inside edges. IF I were to do it again, I would increase the side lip to 5/8" or so. The ink line at the top was drawn to insure that the "corner" canloc's would fit. Holes in the support ring are large enough to allow the attachment ring on the camloc's screw side (that's why I would recommend 5/8" wide lip) so that the door will fit flush. The were installed prior to the 'glassing of the angle.
		Photo06.jpg	Another photo of the door assembly and the "thin" edge of the camloc on the lip of the support ring.
		Photo07.jpg	This shows the end rib closure piece. It's the dark gray .032 against the lighter gray primer rib. It's held in place by four #6 screw/nut plates mounted inside the ribs.
		Photo08.jpg	This photo is of the right wing tip. This is a work in progress so you can see the flaws and "opps" (like the two "extra" holes in the hinge corners), the rivet spacing is up to you. Tom, Gummibear, thinks I over built, I used approx 1" spacing for rivets. I used a rivet fan to get equal spacing so 1" is only approx.
		Photo09.jpg	This support ring is not primered but the camloc's are a better fit on the 1/2" lip. 'Glass over the unprimered hinge. The primered rib closure with screw is visible.
		Photo10.jpg	Overview of right wing tip storage area.
		Photo11.jpg	This is HRII N561FS (USAF 561st. Fighter Squadron, Gummi's old outfit). Right side shows the adjustable air vents. They're the small doors on the right side. Pilot intake is right at the front of the tip over, backseaters is just behind the roll bar. Will take photos of these if anyone has an interest. Steps in order. Tips were taken off to work on them. #1: Draw and cut out the doors. We used a drumel tool with a thin cutter wheel and finished the corners with a thin saw blade. Be very careful on the this cut, as it will become your gap.
		Photo12.jpg	#2: Fabricate the support ring from .040 sheet stock. (We had enough scrap aluminum for both the support rings and the rib closures) Do the rivet layout on the wing tip, clamp the support ring in place and drill pilot holes thru both fiberglass and support. Prime the ring, debur etc. etc. #3: Cut and fit hinge and shims to the opening in the ring. #4: Fit and rivet the support ring and hinge (both halves) to the wing top. #5: Fit and rivet the door, shims etc to proper alignment. #6: Fit, drill and rivet the door to the hinge. #7: Drill pilot holes for Camloc's. Make sure of lip and corner alignments. #8: Go fly..... KABONG
		Photo13.jpg	Photo 13