7
Fresh Aero FlightLights
LED
Taxi/Landing/Recognition Light
for Sonex, RV & Other Homebuilt Aircraft
Installing the Taxi/Landing Light …
continued
1.3
Locate the Bracket Mounting Template at the back of this manual and cut out the center
section on the outside red line. Locate the template cutout on the rib with the rib flange
facing away and center the template with the forward line aligned with the flange
forward vertical end. Secure the template with tape at this position.
1.4 Use a spring loaded center punch , awl or similar tool to “spot” holes in the center of the
two bracket attach hole locations on the template. Remove the template and drill/deburr
the holes.
Note:
the bracket holes are 11/64 inch (clearance for 8-32 screws). Use this size drill if you’re
using 8-32 screws. We don’t include the screws because some builders may choose to use
pulled rivets. If this applies to you, just drill the holes for the rivets you use.
Note:
we do offer “EasyNut” kits for finished aircraft. This kit significantly facilitates the bracket
mounting procedure on finished aircraft. Please contact us for more information.
1.5
Move the template to the opposite rib (the rib with he rib flange facing towards you).
Align and secure the template as in step 1.3. Spot, drill and deburr the holes in flange as
in step 1.4. Remove the template.
Note:
You will need to trim the upper and lower edges of the template slightly to eliminate flange
interference as explained on the template.
1.6 Hold the brackets in place on the ribs and confirm that the opening between the brackets
(where the light box attaches) is centered between the rib rivet lines (see note below). If
not, reverse the brackets, rib to rib.
Note:
The brackets are different lengths! We do this to center the TLR Light between the rivet
lines on the ribs for symmetry. The rivet lines are offset from the ribs so we offset the brackets
too. It just looks better on the finished aircraft.
1.7 Temporally mount the brackets to the light box with the 5 mm hex head screws and insert
the assembly into position between the ribs. Confirm that the assembly fits properly be-
tween the ribs. If the assembly is too snug, bend the middle of the brackets slightly to
achieve the correct fit, then bend the bracket flanges for parallelism. If the assembly is
loose, add washers to each side for the proper fit.
1.8 When proper positioning and fit is achieved, mount the brackets to the ribs using your
choice of fasteners.
