After I finished opening up all of the holes in the Landing Light Lens Support Frame I turned my attention to the Landing Light Lens again. I quickly discovered that the #10 Plexiglass drill bit made some very nice, smooth, clean holes in the Plexiglass Lens but the holes were too small for the pilot on my #10 countersinking bit (Image 1). Not wanting to damage the Plexiglass Lens I decided to tightly roll a small piece of Emery Cloth and then use it like a reamer to slightly enlarge the holes. It took a few minutes for each hole and I quickly started wearing a pair of leather gloves to save the skin on my hands but it did work (Image 2). In Image 3 you can see me countersinking the holes using my microstop countersink cage.
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