Up at 545am hoping to get a good long session in on this 4th of July holiday. I started back where I left off, opening up the landing light lense hole. I used a dremmel with a sanding drum to get very close to the line (1/16") and then used my scotbrite wheel on an air grinder to smooth it out and open it up alittle more. Then I sanded with emery cloth annd called it good. I'm happy with the way it looks. Not a hard job, but ripe with opportunities to ruin your whole day. I then worked up the template for drilling the ribs that will hold the landing light assembly inside the wing. I drilled the holes and installed the nutplates per the plans. Next I countersunk and installed nutplates on the assembly for the landing light retainer and installed everything in the wing (tight fit!). Then I marked off the lense for trimming. I used the dremmel with a cut-off wheel and smoothed out on the bench grinder using the rock! Yeah, sounds crazy, but it works good (thanks Dan Checkoway!). I smoothed it out alittle on the 3M wheel on that same grinder and then sanded with 240grit. Next step is to drill and counter sink the lense for mounting - my last opportunity for a major malfunction - cracking the plexiglass while drilling. Hopefully, my luck will hold out.
Getting the hole ever closer to being finsihed using the dremmel with a sanding drum.
Hole is done.
Masking tape protects the lense while the rock does it's thing!
