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Zenith CruZer & Sonex Logs
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Date: 3-1-2009
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Number of Hours: 1.40
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Manual Reference: n/a
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Brief Description: Landing Light Lens Install
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Now that the flap and aileron for the left wing are complete, I went back to finish the landing light install. All hardware had been installed previously; all that needed installation was the lens.
This is a challenge to describe; the Duckworks landing light kit is VERY well documented and equipped, but this is not part of the normal Sonex plans, so some may not understand the intricacies. Plus, I took far more photos than could be documented in kitlog due to the 3 pic limit.
Anyway, to start, I covered the lens in blue masking tape, and constructed a "handle" of two pieces of duct tape to pull it tight for trial fitting.
Put the lens into the wing and pulled the "handle" tight. Drew outline of wing cutout onto the taped lens. From there, you first measure and cut the edge of the lens to allow it to fit into the retaining strip on the top surface of the wing. You also trim the overall width of the lense to 6.5". Since it starts out at 7", it's unclear why you have to trim .25" off each side, unless it's to get rid of slight waviness that's part of the original formation process.
Then you position the lens back into the wing, and mark the location of the bottom retainer strip retaining screws onto the tape. You mark cut lines based on these holes, and mount the lens to the bottom strip with packing tape (just have to hold it until the screws grab).
Mine fit fine as a result. There is a slight gap only at the front nose of the wing which could be taken out by shimming the bottom retainer just a bit. I also have not yet installed the foam sealing tape around the hole, so will make some final adjustments when that is done. Just had to include a picture of it lit.
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Trimmed w/retainer strip attached
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Installed
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Lit (wing is upside down on bench)
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