
This time I was shaping the wingtips. Did most of the work on the foam, then made some plywood backing inserts for the nav/strobe/position lights. Happened upon a good technique: The inserts are 1/4 inch plywood which I mounted with flox to the foam, then applied very thick micro paste to fair them into the existing foam shape (which was previously "sealed" with micro and sanded smooth). Once the micro-paste began to set up, I put peel ply over it and stretched the peel ply back into the contour of the foam. This made a beautiful contour on the micro that only needed minor touch-up sanding. Video shows the process and the finished product mated to the Aveo Engineering nav/strobe/position lights.
BTW, I put the lights on the bench to test and they are incredibly bright, have good strobes, and are a sealed unit weighing a few ounces with nothing to mount inside the plane. Current draw is 0.25 amps for the nav/position lights going up to 1.8 amps when the strobe fires (per side). Boy am I glad I took so long to finish my plane..All this cool stuff to put on it now. ;-)