With the drilled Landing Light Lens in place I used a Sharpie to mark where the matching holes should be in the Landing Light Lens Mounting Frame and then carefully drilled the matching holes. I was worried about using my standard drill bits in contact with the Plexiglass Lens so I decided that if I was careful I could drill these holes (which will be oversize to allow for the dissimilar rates of thermal expansion between Plexiglass and Aluminum) accurately enough. Image 1 shows me drilling those holes. I was almost right. I managed to drill all but one hole in the Mounting Frame what looked to be dead center to the Sharpie mark but one wandered. So I made a tool from some of the 1/4" Aluminum strip I bought and using my drill press made a tool that I could cleco in place and then drill the final oversize hole where I needed it. The tool is shown ready to be used in Image 2 and it worked as desired to put the hole where it belonged. Image 3 shows me using a Platenut Drill Jig again to drill the holes for the Floating Platenuts that will fasten the Landing Light Lens in place.
Drilling the Matching Holes in the Landing Light Lens Mounting Frame
Using a Tool to Properly Locate a Hole that Wandered
Drilling the Landing Light Lens Mounting Frame for Platenuts
