Wing Tip Lens Cover

[David Weber]

I have an Original BH. Kit 26 and the original wingtips. Has anyone found a clear lens that can be used for tip lights?

I am wondering if there might be an automotive lens that could be modified to work.

[JoHo]

I think at least one builder has re-formed Vans parts to fit.

I am working on a leading edge landing light lens and nave/strobe combo out on the tip. With just a light in the corner of the tip, an additional rear mounted light will be needed for night flight.

[Nev]

I made one using 3mm acrylic formed around the leading edge and heated with a heat gun. Didn't take long. Use a couple of tie-down straps to hold the sheet in place while you heat it. Then cut it out with a cut-off wheel in an angle grinder. Drill the holes with a step drill and countersink them for dimpled flush #6 screws.

I've riveted a vertical support that the light attaches to - it provides added strength and stiffening to the wing skins in the outer bay.

5AD33932-238E-495D-BDF8-5CE904C4A029.jpg
4D133E66-E2D0-4FAD-A78B-0089EA2A222B.jpg

[Utah-Jay]

Nice work Nev, I may just copy that method

[alaskabearhawk]

I have the "original" wing tips and didn't find anything that would work. I tried both manufacturers of the RV wingtip lenses and they didn't work and sold them at a loss. I even called a PMA supplier of wingtip lenses for many, many different types of aircraft. I sent them one of my close, but not quite good enough, attempts at forming my own and asked them if they could find something that was close and they came up with nothing. I finally succeeded in making my own, but only after a significant amount of trial and error. I did learn a lot though about heat forming plastic and I guess that's the purpose of homebuilding.

Here is the first of my 20 part (yes, 20...yuck) series on wingtip light lenses: http://www.mykitlog.com/users/displa...=274286&row=50

And here's the last. My last writeup says it all: http://www.mykitlog.com/users/displa...=284398&row=14

I know that some cut holes in their leading edge toward the wingtip to install lights, but Bob does not recommend this at all as it compromises some of the wing structure (i.e. wing skin). Read whee's response here, about nine posts down. He sums it up nicely: https://bearhawkforums.com/forum/too...-flying-patrol

[Enewton57]

Here is what I did way back when.

http://mybearhawk.com/finish/tips2.html

Eric Newton
Bearhawk Tailwheels LLC

[alaskabearhawk]

Leaving the wingtips intact in forming the RV lenses is key. I had already cut mine and then it was too late.