Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
11
Fitting the Lens …
continued
Caution:
Use proper acrylic plastic cutting and stock removal procedures when trimming lens. Do not use
snips or any other tool that would crack or damage the acrylic.
Remember, during the lens trimming process, it’s better to trim conservatively, then slowly remove access
material with subsequent adjustments.
3.17 Loosen the bottom retainer screws until they are flush with the retainer top surface. Push up on
lower retainer and lean it as far aft as you can (photo 13) If retainer falls back down, use a
strip of tape across the screw heads and skin to hold the retainer up.
4. The Final Fitting
4.1
Remove a few top layers of tape from the apex of the lens for viewing through the lens in
subsequent steps.
4.2 Attach the tape handle to lens once again, making sure edges of the tape are folded around the
ends of lens surface for better adherence. You might want to construct a new handle if your
current one has lost its holding power. This will eliminate the any frustration that may occur if
tape slips off during the following steps.
4.3 With the upper lens retainer in place (
upper retainer screws may need to be loosened slightly to
facilitate lens insertion),
and with lower retainer raised, carefully install the lens, confirming that
lower edge of lens fits between the lower wings skin and raised lower retainer (Photo 13). The
edge of lens should be tight against the threads of the screws. This step allows the lens lower
edge to be rotated aft and provide clearance for the lens upper ledge to be inserted back under
the upper retainer’s retaining pocket.
Note:
make sure the side to side center lines at top are aligned before rotating lens into retainer pocket.
4.4 Confirm that the lens top edge is properly seated into the the top retainer pocket and that bottom
edge of lens is located between lower retainer and skin by viewing the retainers through the lens.
4.5 Pull down on the lower retainer using the two 5/8“ screws, confirming that the bottom of the
retainer mates tightly with the skin of the wing. If not seated properly, pull the lens forward
with the handle to seat the retainer There are two indicators to look for – a “through the lens”
visual inspection of the retainer mating tightly against the skin and the perpendicular
orientation of the screws attached to the retainer at the bottom of the wing.
Note:
E
xternal lighting may help to confirm the retainer to lens fit between the retainer pockets and skin.
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