November 17, 2008 ...  I finished fabricating  and polishing the reflector pieces that will attach to the ribs, and bolted the landing light attach plate into place.

November 18, 2008 ...  After installing the leading edge (with Clecos),  I drew in the landing light opening and made the cutout.  I am going to be making the landing light lense out of 1/16th inch Lexan. I also surfed the internet for some ideas on how to install the lense. I found some really great instructions (PDF File) at this website:  http://www.t18.net/resources/Landing%20Light%20Instructions.pdf .          
    The instructions are aimed at building a Thorpe T-18, but they can easily be adapted to a Sonex.       
I spent the rest of my "wing" time working on a fairing pod for my NAV/strobe unit which will eventually be made out of fiberglass..

 

The first step was to make a prototype out of clay which will eventually become a form to create a Plaster of Paris mold. I used a modelling clay that can be oven-hardened, and is available at many hobby shops.     

Notice that I set the clay on a board with a 45 degree angle. I used that angle as a reference to set the sloped surface where the NAV light will attach. I then made a template of the NAV light base out of .025 aluminum scrap,  which helped me accurately shape the clay.
Now I need to give my "masterpiece" a chance to dry for several days before I oven-harden it.

 

November 22, 2008 ...  My NAV light clay form is still in the final stages of drying. So back to the landing light project ... Today, I made a form which will be used to shape the landing light lense. Using one of the pre-formed ribs as a template, I constructed a support that conforms to the shape of the wing leading edge. and formed a piece of scrap .025 aluminum sheeting around a 12 inch length of 1 1/2 inch diameter pipe. I pre-drilled the aluminum and fastened it to the wood form with 6-32 screws. Also, notice that I riveted stiffener brackets along the bottom edges of the metal to help it hold it's shape. I made the form larger than the actual lense itself so the fasteners would not interfere while shaping the Lexan.