Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
10
Fitting the Lens …
continued
3.12 Pull on the bottom of the tape handle with one hand and rotate and guide the lens into the top
retainer pocket until seated. Check the center marks and tracings to confirm lens is fully
engaged in the pocket of the top retainer. If trimming is required, remove lens and use a file or
sanding device to complete final finessing of the upper edge. Reinstall the lens
.
3.13 With tape handle in place, lens seated in the top retainer pocket and the center lines aligned,
pull the bottom of the handle against the lens opening with moderate force which should rotate
lens slightly and snug front lens profile to the leading edge skin. Gently tighten the upper
retainer screws.
Note:
If a friend or family member is available to help this
would be a good time to ask for assistance.
Very Important:
Pull consistently on the lens to confirm
that the lower trace line is still positioned at the opening
cutout. If not, draw a new line with a different color pen-
cil or marker. Release and apply pull force again to check
for repeating results. THIS STEP WILL AFFECT FINAL
APPEARANCE AND FIT.
3.14 Remove lens and install lower retainer with two
of the four included 5/8 inch long 4-40 screws in
the two inboard holes. Push back slightly on the
retainer and lightly tighten the screws. Use a
scale or thin measuring tool to measure the dis-
tance from the rear of the retainer’s lens pocket
(the back of the pocket) to the edge of the lens
opening on the wing.
3.15 Using the line on the lens identified in step 3.6,
add the dimension obtained in step 3.14, aft of
this line (towards the rear of the lens), and draw a line aft and parallel to the original line. The
added distance should be about 5/8 inch if the lower retainer was installed properly.
3.16 Trim the lens bottom edge to match the line drawn in step 3.15. There is no profile to match
during this operation, just a straight cut as the lower retainer does not have the lateral guides.
Caution:
When trimming lens, be sure to leave additional material for fitting! Once material is removed, you
can not replace it We recommend leaving at least 1/16 inch extra material for first lower retainer trial fit.
Also additional material will allow for small discrepancies during roughing operation and for correcting any
lower retainer misalignment.
13
Lower retainer raised and
leaning back
