After I finished opening up all of the holes in the Landing Light Lens Support Frame I turned my attention to the Landing Light Lens again. I quickly discovered that the #10 Plexiglass drill bit made some very nice, smooth, clean holes in the Plexiglass Lens but the holes were too small for the pilot on my #10 countersinking bit (Image 1). Not wanting to damage the Plexiglass Lens I decided to tightly roll a small piece of Emery Cloth and then use it like a reamer to slightly enlarge the holes. It took a few minutes for each hole and I quickly started wearing a pair of leather gloves to save the skin on my hands but it did work (Image 2). In Image 3 you can see me countersinking the holes using my microstop countersink cage.
Using Emery Cloth to Slightly Increase Diameter of Fastener Hole in Landing Light Lens
Using Emery Cloth to Slightly Increase Diameter of Fastener Hole in Landing Light Lens
Countersinking Landing Light Lens Fastener Holes using Microstop Cage