I slid the plexi lens inside the cutout in the wing. Then used the tape “handle” to pull the lens tight against the skin and drilled the mounting holes to #40, installing clecos as I went. After all holes were drilled, I took everything apart and deburred the skin and very lightly deburred the plexi. Then, put it all back together again and drilled the first #30 hole thru the skin and plexi. Didn’t really like drilling both at the same time—takes a bit of pressure to get thru the skin, but you want very light pressure on the plexi. Removed the plexi and deburred the #30 hole. Then I drilled a #30 in the skin top and bottom and put the plexi back inside the wing. Clecoed all of the #40 holes and then drilled a couple of #30 holes using the skin as a drill guide. This seemed to work much better than drilling the skin and plexi a the same time. Rather a slow method-taking it apart, cleaning up the burrs, drilling a few #30 holes thru the skin, putting it back together, drilling the plexi while using the skin as a guide. Whew! Kinda wordie, but you get the idea.
