I received the shipment of landing light plexiglass replacements from Vans and went to work. This time I enlarged the screw holes slightly on the plexiglass and made sure there were no seemingly minor imperfections in the holes. I re-dimpled the screw holes in the wing skin to a slightly larger dimple size 6 so the screws would be flush (the prior time was a smaller dimple and the screws didn't set well). I cut the plexiglass to where it perfectly fits the nut plate brackets (no extra plexiglass beyond the edges) and insured the plexiglass curvature matched the skin leading edge. A perfect fit, so this time I installed the screws with locktight to insure they would stay, and I tightened them just to the point I could see the screws protruding from the nutplate ends, and the screws set mostly flush. I didn't dare tighten them to the point it stopped like last time. After inspecting it, even weeks later, it has not cracked this time. I may tighten a couple of the end screws a little more so the screws set totally flush, but I'm nervous about tightening them too much. Whew!
