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The Redheads RV-7A Build SIte
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Date:  9-10-2010
Number of Hours:  2.00
Manual Reference:  Lighting
Brief Description:  Preparing for Landing Lights

I let the 3/32" plywood skin dry for 4 days before removing the band clamps. Because I had gone into work over the Labor Day Weekend to make some charts for an important presentation I had used up my week by Thursday and had Friday off. So I spent some time working on the airplane. Getting ready to cut some plexiglas, Image 1 shows how I taped over all of the slots in the band saw cutting base so that no sharp metal edges were exposed. Because my idea for a retainer had worked so well with the 3/32" plywood I decided to follow that example for the plexiglas. I found a pair of wood paint stirrers that were very nearly 0.10 inch thick and cut a piece of scrap 0.025 aluminum sheet to make a 0.125 inch thick shim. Image 2 shows me cutting the 0.025 inch aluminum shim. This I carefully located on what would be the top side of the leading edge form. This would both hold the plexiglas in place while it was in the oven and ensure that I got a consistent placement on my lenses. I bought some cotton flannel to cover the wood form with. One set of instructions I found on the web said to use cotton flannel and another said to use flet. When I went to the local fabric store the felt was much thicker and had a coarser texture so I chose the flannel. Image 3 shows the completed plexiglas retainer installed on the flannel covered form. A test piece of plexiglas is shown in the retainer, ready to be put into the oven.
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Band Saw Taped to Prevent Scratching of Plexiglas

Band Saw Taped to Prevent Scratching of Plexiglas

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Cutting Aluminum Shim for Plexiglas Retainer

Cutting Aluminum Shim for Plexiglas Retainer

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Plexiglas Retainer Installed on Form After Flannel is Stapled in Place

Plexiglas Retainer Installed on Form After Flannel is Stapled in Place

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