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Date:  10-10-2010
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Started cutting out the leading edge for the landi

The template for the leading edge cutout for the landing/taxi light has corners of about 1.25" radius, so I figured a 2.5" hole saw would do a good job. I had just seen a video on the EAA website about using a wooden disc template, cut out with the hole saw that you intend to use it with. It was actually shown for instrument panel holes, but thought it would work well here.

The corners on the bottom of the leading edge were pretty straightforward, since the location is nearly flat, and the disc can be held in place with the hole in the center. Not so with the top. (Actually, the top corners were not cut until November 6, but had more pictures than the Nov. 6 page would hold, so put them here.) Due to the curvature of the leading edge, the center hole would not work, so had to use the old eye-crometer to fasten the disc in the right location. Worked pretty good for one corner. The next one wasn't so easy.
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The setup for cutting out the rounded corners with the hole saw.

The setup for cutting out the rounded corners with the hole saw.

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A little trickier setting up for the top of the cutout, due to the curvature of the leading edge.

A little trickier setting up for the top of the cutout, due to the curvature of the leading edge.

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Seems to line up OK.

Seems to line up OK.

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