I recently completed installation of the Gallagher wingtip STC’d brackets, LED recognition, position and strobe light kit. I also bought the Max pulse light controller and wire from Gallagher as well to complete the installation. Additionally I bought the WAT LED beacon from James to round out all of my lights to LED. In a word the lights are FANTASTIC!
Installation is straight forward. Here is a quick synopsis. All work was mostly done by me while supervised by my A&P. I started with the Beacon. My old one was a Whelen strobe type Red in front and white at the rear mounted on top of the rear fuselage. Removed my old beacon by removing the mounting flange, and separated the old beacon from the flange by removing three screws and cutting away some old sealant. The leads to the new beacon WAT 9052055 comes with molex connectors, so simple connection of the molex to the existing wire with some environmental splices. (Pay attention to polarity as the LED’s are polarity sensitive). Remounted to the flange and resealed with silicone sealant.
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Inspired by these results, I jumped into the wingtip and tail lights. I had the original Grimes wingtip and tail strobes. The old Grimes strobe controller was mounted in the tail just aft of the rear baggage bulkhead. Easy access to that area, I removed the strobe controller and used the existing wiring form the old strobe lights for the new strobe lights. This was fairly straightforward. I used the circuit breaker protected power-in to the old strobe controller and spliced this into the old strobe wires out to the old strobe lights. (This required me to cut the old barrel type connectors off of the old wires). The old wire is self contained in a bundle and There are three wires in the bundle going to each strobe - tail, right wingtip, left wingtip -actually four wires really, positive, negative, and strobe and a shield). I connected these wires at the old strobe controller end. All three Red to positive, 3 black to ground, and the 3 clear to themselves- these will connect all three strobes to each other and thus will sync the flash.
I then went to the tail, removed my tail cone and removed the Grimes combination white position light and strobe. I wired the new WAT tail strobe (WAT Orion 5001V) positive to the red, negative to the black and clear to the sync. I identified the existing NAV light positive lead going to the rear white position Light and wired that to the new white position light.
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Next I moved to the wing tips. I removed my wingtips and disconnected the strobes and the position light connections. I needed an extra pair of wires to energize the wingtip recognition lights that come with the Gallagher kit. I removed inspection plates under the wings. I used a 10 foot section of flexible plastic electrical conduit placed in the wingtip and pushed it into the wing, sometimes helping it by reaching up in the inspection holes to route through the wing up to the outer gear wheel well bulkhead. I pushed the new wire I got from James (M27500-18TG2T14) through the conduit. I fished the wire through the wheel well bulkhead around the main landing gear following the exiting wiring routes.
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I found this interesting in my left wing; some Beechcraft factory guy was an artist? Makes me wonder if anyone else has drawing inside their aircraft?
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To get the wire routed through the inner gear door, I found it best to jack the airplane and function the gear enough to open the inner gear doors. This gave me room to work and to route the wire alongside the exiting wiring bundle.
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The next part was the hardest (but not too hard), the holes for the wing bulkhead where the wing mates to the fuselage do not line up to the holes for the wire in the fuselage, I removed the inner interior panel and snaked a fish wire down from inside the airplane into the slot that you can see from underneath the airplane when you have the jack pad covers removed. I used that wire to pull the new wire through the existing wire bundle into the cockpit.
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I ran both wingtip recognition light wires into the cockpit and connected to the MaxPluse controller that I installed in my panel. The MaxPluse requires power and connections are straightforward. I wired my max pulse power to my landing light power thus requiring my landing light to be ON for the recognition lights to function. The MaxPluse has multiple options, to include OFF, ON, left only, right only, Alternating L/R at 44 bpm, both flash at 44 bpm, alternating at 88 bpm and alternating at 120 bpm.
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Now back to the wingtips; I removed the old strobe boxes (the rectangular sized Grimes style boxes and nav lights).
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I painted the interior portion of the wingtip white and mounted the Gallagher bracket using the hardware provided. It does require riveting the light bracket to the main bracket. I mounted the Recognition light and the combo position/strobe light to the bracket. It is a clean, straightforward process. The recognition light bracket provides for adjustment up and down. (The recognition light is the 20 degree WAT model 7112511 and the position/strobe is the WAT Orion model 6501GE/RE).
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At the wing, I connected the strobes using the existing old strobe wires consistent with the wiring I did at the other end, at the old strobe controller - positive to red, black to ground and clear to sync. I used the existing NAV light wires to connect to the new NAV light leads. I connected the new wires I ran to the recognition lights, positive, and ground. I used modular connectors for future ease of removal and reinstallation.
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Added comments; there are separate STC’s for the brackets, the MaxPluse controller, the Wingtip and tail position/strobe lights, and the beacon, so I had my A&P IA complete 337’s for the installation. I sold all my old lights and controller (with the exception of the tail light/strobe which I had to cannibalize to get the bracket to mount the new one), which helped me out in costs and maybe helped others to keep some legacy lights working.
I am a huge fan of this set up and really enjoyed the process of installation; but the results are even better. The LED’s are very bright and use very little power. I previously had installed LED landing and taxi lights, so with this set up I am completely LED’d!!