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Kupe's Zodiac 650B
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Date:  9-15-2013
Number of Hours:  2.00
Manual Reference:  6-LLO-1
Brief Description:  Landing/Taxi Light Lens Install

Performed final fitting and installation of the landing/taxi light lens cover. I had pretty much finished fitting the lens (this one's the replacement lens for the one I broke trying to fit it a few weeks ago!) so now I had to fit a 20mm wide metal strip to the top and bottom edges of the lens cover to protect the acrylic from the screws that hold the cover in place. My solution for attaching the strip was good old Scotch double-sided tape.

Next, I needed to determine where to drill the leading edge for the 4 screw holes (each) on the top and bottom of the light assembly. To do this, I I fashioned another tool (see image 3) by:
1. Cutting 2 identical metal strips from scrap wing skin
2. riveting the 2 strips together so they were even with each other
3. bending a small 90 degree angle, like a hook, at the end of the "bottom strip"
4. Drilling a pilot hole through both strips 10 mm from the tip.

By sliding the hook part between the leading edge skin and the lens cover with the flat part of the tool on the outside of the skin, I can simultaneously pull the lens snugly against the inside of the leading edge while having a pilot hole on the skin surface to mark the skin when the lens is precisely where I want it. Using the skin marks I made, I laid out straight lines on the top and bottom of the leading edge skin, removed the lens, drilled 4, evenly-spaced pilot holes on that line, replaced the lens, pulled it snugly into position, then marked the lens through the pilot holes. One last lens removal to drill them out where they were marked and a final reinstallation to drive sheet metal screws through the lens to hold it in place.
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The finished lens cover. Note the 4 sheet metal screws holding it in place.

The finished lens cover. Note the 4 sheet metal screws holding it in place.

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The completed landing/taxi light assembly, with lens cover.

The completed landing/taxi light assembly, with lens cover.

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The

The "snugging and marking" tool I made to pull the lens tight against the skin and then mark it.

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