Some time ago, I received a large package from Aveo containing a brand new set of their ZipTips, wing tips with slick looking LED’s. I’ve been waiting on these things for years, ever since I saw them at Sun ‘N Fun in 2013. I’ve hounded poor Damien at Aveo relentlessly but it paid off with an opportunity to help them out with profile shaping and some prototype testing. In the end, I think it was worth the wait and I’m really looking forward to seeing these things all completed.

Now, because I was helping out, I received the prototype of the light modules and to say it nicely, they’ve been through a tough time. Unpacking the box, there were a few things rattling around and the back of the light module had come off.

First order of business was to test out the light modules. There is a 16 pin CPC with pigtails included, but the wires weren’t pinned out accurately causing me a few scares that I had shorted out the board or LEDs. After a few emails and testing, I was able to re-pin and document the proper wiring schematic. I did this for both sides and then took the time to re-seal the modules closed using some silicone and fresh hardware.

As others have said, these things are crazy bright! I hooked them up outside just to see what could be lit up and man, I am really impressed. Pictures and video don’t really do justice, but let’s say that I’ve flown many Pipers and Cessnas that have less than half of even one of these landing lights. Combined with the Aerosport taxi light, I think I’ll be able to light up the night just fine.

After testing, I started to do a rough fit and trim, but then they got put to the side waiting on the piano hinges that I planned to use to mount them. A year later, it’s time to finish them up so that I can call the wings complete. The first step was to complete the trim using the methods followed by others to install the tips with hidden piano hinges instead of screws and nut plates. I won’t go into detail as it’s documented on plenty of other build logs and forums out there such as VAF. Taking my time, I was able to get a really nice fit and used the cut off wheel on a die grinder just as I did with the cabin top.

I did run into some interference with the light module mounting hardware that butted up against the end rib. After talking to Van’s support, I drilled an accommodating hole in the rib to allow the hardware to protrude inward through the rib and let the tip sit flush against the skin. Once I had the hinges on, I split the trailing edge to reposition and line up with the ailerons. This is a common practice, even on the stock tips and was fairly straightforward. After a bit of work, I had a nice straight line from flap to tip.

Finally, I received some stainless steel hardware in for the light module access covers and mounted them with nutplates. Others have used a lot more fasteners than I did, and I’ll probably go back and add a few more before first flight. I painted the inside of the light area black to give the lights a meaner and cleaner look. I also painted the outside of the light reflectors, again, just for cosmetic purposes. Next up will be to run the wiring through the wings, mount the archer antenna, and make a pin retainer for the hinges.