Parker came up again this morning to help with the landing light installation. We started by laying the lense against the wing and marking a boarder around the opening for trimming the lense to size. The instructions say to leave 3/4 inch on the top and the bottom and 5/8 inch on the sides. We trimmed the lense using a bandsaw which worked very well with a nice clean cut. The edges of the lense were smoothed using a sanding block and 400 grit. A tape handle was attached to the top and bottom of the lense to be able to pull it forward and hold in place against the wing for drilling. Drilled thru the wing into the lense first with a number 40 bit. Then, using a number 30 plastic/laminate bit the hole was increased. We removed the lense and clean the holes and then they were increased to 5/32 with another plastic/laminate bit. The holes in wing were also increased to 5/32. All holes deburred well to prevent any cracks in the lense. Used a #21 countersink on the lense holes just deep enough to accept dimples in the wing for a #6 crew. The retaining strip rivet holes were countersinked and K-1000-6 nut plates were installed.
Marking the lense for trimming.
Drilling thru the wing holes into the lense and cleco.
Lense drilled and countersink, nut plates on retaining strips.
