Tail Position Light
Got the taillight mounted on the lower rudder. Like so many tasks this took far longer to do then it should've. It utilized the wiring harness installed in the aft fuselage cone ages ago when I was building that component. The wiring is run through the vertical stab aft spar and to the rudder and tweaked to achieve the proper length. It had to flex throughout the entire rudder range of motion, not be too tight, rub on anything or droop excessively when slack. Once achieved RTV sealant is used to secure the wiring where it penetrates through the aft fuselage bulkhead so it neither shortens or lengthens as the rudder moves. I used a different bolt on the vertical stab for the ground wire then the plans called for to solve some rubbing issues. Then I crimped on the Molex connector pins to the 4 wires coming off the light assembly. Per plans I used female pins. The Vans' harness already had the pins installed on the 4 lighting wires and I only had to install the connector. I wish I'd looked at those pre-installed pins closer. To my great annoyance I discovered (too late) the Van's harness had female pins installed instead male pins per plans. This caused a lot of hassle because removing the female pins from the connector on the light was problematic, even with the right tools. I didn't care about preserving the pins but I needed the connector housing. After struggling through that I re-crimped male pins and a connector on the light, got everything hooked up inside the fairing and secured with tie wraps. I used a jig to countersink the rudder fairing mounting screw holes deeper so the screw heads would sit only slightly proud. I purchased a few countersunk Tinnerman washers and temporarily installed them to see if I prefer that look vs the no washer/screw only look. I'm concerned about long term stress cracking around the screw holes.