From Bondline
Whelen Flashing Strobe Install
I had already installed the Red Rudder Cap using the original light fixture. When the power supply went bad it was time to upgrade to the Whelen Strobe for the rudder cap.
Whelen parts:
Model A 625 strobe light assembly (current part number "A625 strobe").
Model HTS,CF strobe power supply (new part #A490ATSC)"strobe power supply".
Model HS-5 Whelen installation kit/wiring harness.
The install is straight forward however the rudder will need to be rebalanced. The Maintenance Manual covers this well.
Rough dimensional sketch.
The original bracket for the standard bulb and the new one for the whelen strobe, note light shield.
A bracket to mount the A 625 light will have to be fabricated as well as the HTS,CF power supply. I used the dimensions outlined on the sketch to make the bracket. As indicated a slot will have to be cut on the rear side of the bracket to allow the wiring harness to pass through.
Additionally a light shield is fabricated and attached to the bracket to shield the strobe light from flashing forward and distracting the pilot. The bracket is attached to the rudder horn and the wires routed.
Strobe with light shield.
To rebalance the rudder I removed the original lead weight and fabricated a larger one that would still bolt into the existing location. This was done by making a mold out of aluminum foil and placing it in a large coffee can filled with sand to support the foil. I then melted the original lead and additional fishing weights in another can using a propane torch and poured it into my mold. I used more lead than I calculated cause its easier to cut it off then add it. I also had to drill two holes in it. The actual weight adjustment to just add the strobe vs standard light is not much. I used most of the additional lead when I originally added the red rudder cap and placed the original flashing beacon inside. The loss of the upright red "jelly jar" is a few ounces.
View of the new lead weight.
I attached the power supply below the vertical in the area where the original flasher power supply was located. The Whelen power supply does not have any legs or standoffs attached to it. The area where I wanted to mount it is not flat, it has a raised lip from the lightening hole. So I made some spacers to support the power supply yet raise it high enough to clear the lip and then bolted it down.
Aluminum spacers to raise and support the power supply.
I used the original power supply for the flasher to power the Whelen unit so no wires were run forward, just a new harness from the power supply to the strobe that come from Whelen. The red rudder cap has its own STC and Whelen has an STC to cover the strobe and power supply install. "
Whelen power supply, strobes, installation instructions and STC's"
