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Bill & Brendas RV-8 QB
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Date:  7-11-2011
Number of Hours:  6.00
Manual Reference:  
Brief Description:  landing light- left wing

Today we arrived early to beat the heat.
1. Rcd new plexi lens from Van's so I got it marked up for cutting and cut off the excess plexi with dremel tool on top and bottom edges and one side. This leaves a 3/4 inch overlap on top and bottom edges. The sides have a 5/8 inch overlap.

2. Using a newly purchased belt sander, I flat sanded with 120 grit down to final marks and also rounded the corners. I then used a sanding block and further sanded the edges smooth. Final finish sanding was done with wet/dry fine paper and water.

3. Drilled the 3 holes top and bottom in plexi first to #40 and then to 5/32 with a unibit. I then counter sunk the holes to accept the #6 dimple in the skin.

4. Drilled the lens retaining strips screw holes to 5/32 and counter sunk the rivit holes for flush rivits. Attached the 3 nut plates to strips top and bottom. Applied double sided tape to each side of the screw holes on retainer strips and attached them to the plexi.

5. Holes in skin were drilled to #30 and then slightly inlarged to accept the #6 dimple die. Then dimpled the holes in skin top and bottom.

6. Inserted the lens in wing and secured with the screws.

This took a long time but was nextra careful since I had messed the first lens up!
I will need to remove the lens and tape from inside, attach the weather stripping and re install but will do this later after I finish the other wing.

Temp in hangar at 90 and increasing. Time to go home!
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Cutting the plexi lens with dremel and plastics cut off wheel

Cutting the plexi lens with dremel and plastics cut off wheel

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Strapping tape handle to pull lens up snug for drilling

Strapping tape handle to pull lens up snug for drilling

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Lens installed with #6 screws top and bottom

Lens installed with #6 screws top and bottom

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