after I marked the lens against the opening I had already cut in the leading edge I covered the lens in blue painters tape and cut the rough shape of both lenses on my band saw. I then deviated from the instructions and held the lens snuggly in the opening(the tape didn't work well for me and my leading edge was not on the spar, YMMV) with my hand and drilled the #40 holes carefully clecoing as I went. I then pulled the lens off, cleaned the holes and drilled through the skin and lens with a #30.
I grabbed a screw and looked at the #40 hole...this didn't look right. I refferd to my mechanics tool box and found theright size hole for a #6 screw, tried it on a test piece, dimpled and liked the fit much better. My tech inspector had lent me his #6 dimple die set and I dimpled the skin for the first lens using the #6 dimple dies.
