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Ron Lendon's Aircraft Mfg.
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Date:  3-7-2007
Number of Hours:  1.00
Manual Reference:  6LLO-6
Brief Description:  Trim and fit Landing Light Lens

Made a template of Acetate the same length as the backing strips, about 1" bigger than the hole, and transfer it to the lens.

Image 1) Picked up the shape of the top LE and transfered the EOP, (end of part) to the lense to begin the layout. Once the straight line and inboard/outboard edges were established on the lens the rest of the layout was transfered from the template to the lens.

Image 2) Here is the lense with the layout. I have some double lines and will cut to the outside lines. Triming was done with a dremel tool, 1/8" dia spiral 3 flute taper design. The tool was dull and had to be stopped frequently to clear the molten plastic that was getting hard. Had to make a slight angle on the outboard edges, both top and bottom to get it to fit in the hole. It was as far to the inboard as it would go and it was pretty clear what and where the material would have to leave the lens.

Image 3) Paint stirs proped against rag from the inside to press the lens into place before marking holes.
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Shape template for EOP

Shape template for EOP

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Lens layout

Lens layout

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Paint sticks to push lens out

Paint sticks to push lens out

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