Time to make the cuts in the leading edges of my outboard leading edges. I decided to work on the Left Outboard Leading Edge first. The first thing I did was locate the center of the bay where the landing light would be loacated. I decided to put the light in the 2nd bay inboard from the tip. It is wider than the most outboard bay and I wanted to have some distance between the light and my planned "Archer" wingtip antenna so it seemed like the logical location. Image 1 shows one of the landing light lenses laid on top of the leading edge. I used the landing light lens to locate where the back edge of the cutout would be - 1/8 inch further back fromt the actual edge when it was sitting on the leading edge. Using a circle template I located the center of the hole and then used a 2 inch diameter hole saw to cut the corners as shown in Image 2. I had a very difficult time cutting the first two holes as can be seen in Image 3 and after the 2nd hole I figured out why - somehow the drill pilot for the hole saw had gotten bent! I replaced the bent pilot with a new pilot and the next two holes were no problem.
Landing Light Lens Sitting on Leading Edge with Hole Coutour Marked
Using a 2-inch Hole Saw to Cut the Corners for the Landing Light Cutout
Ragged Holes in the Leading Edge Caused by a Bent Pilot Drill
