Cut leading edge for landing light. Debur edges, debur stiffiners, cut plexiglass to fit. Mount nutplates. Cut light bracket.
I should have taken photos of this process but as they say, laws and sausage are best not to be seen during the making. There is something about taking the brand new skin and cutting a hole into it. Lots of measuring, planning, marking and then take the plunge and cut. I used the nibbler to cut the hole into the rough shape then filed, ground, and generally massaged to hole to shape. I trimmed the plexiglass by grinding the shape with the scotchbright wheel. The scotchbright grinds the plastic away and it is easy to make the corners with a nice radius. It requires a light touch as you get the shape correct. The edges are then sanded with 220 grit sandpaper, then buffed with red scotchbright by hand. I finished with a cloth pad in a Dremel tool. Thouroghly sand and buff untill there are no nicks and all the edges are smooth.
