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KENNETH T.'S WEB SITE
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Date: 2-7-2012
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Number of Hours: 4.50
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Manual Reference: Van's directions
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Brief Description: Cut wingtip lenses and fabbed the left tip lens.
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Today after ordering some more electrical terminals, I decided to fabricate the wingtip lenses. I used a hacksaw to cut in half the one piece lens part Van's sent. I taped the left half onto the wingtip cutout and used a Sharpie to mark lines about 1/4" wider that the lens groove around the cutout. Charlotte held the lens as I used the Dremel fiber disc to cut along the lines. I thought it would throw plastic pieces everywhere, but the disc just kind of melted through the lens material (acrylic?) along the marked lines. I then taped the lens on again and marked lines even with the groove recess where the lens will flush up to tip mold line.
I used a block sander with 60 grit sandpaper and "slowly" started approaching the marked lines. I sanded then I fit, sanded, fit, sanded, fit, you get the picture. You don't want to take off too much and have to order another lens. Once it fit, I marked and drilled the screw holes to match the nutplate holes and then countersunk them for the #6 screws.
One down and one to go!
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Sand, fit, sand, fit, etc.
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Photo of lens with just the corner screws installed.
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Photo from another angle.
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