Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
12
The Final Fitting …
continued
If the lower retainer is not mating properly on top of the lens, remove the lens and trim additional
material from the edge. Remember, it may take several attempts to obtain correct “fit” but the
results will be worth the effort. After trimming, repeat the above steps until retainer can be
pulled into place and drawn down properly over the lens (photo 14).
Don’t be concerned if a small gap exists between the lens and inside wing surface, the foam
sealing tape installed in the final assembly will fill this space. This said, the gap should be no
larger than 3/32 inch at any location on the profile.
Note:
we do sell the lens separately, if you inadvertently cut your lens too short or otherwise damage it.
4.6 With the lens still in place, start the remaining two 5/8
inch long 4-40 screws in the outboard holes of the lower
retainer screws and confirm that the screws can be started
easily.
4.7 When you’re satisfied with the lens install fit, remove the
lens by first removing the lower retainer bracket
completely.
Note:
If your light isn’t installed yet, This would be an ideal time to
do it. If you purchased a Fresh Aero TLR Light, please refer to the
TLR Light installation manual now.
4.8 Reinstall lower lens retainer using two 5/8 inch long 4-40
screws in the inboard holes. Position retainer in the
extended, upward, leaning aft position as in step 3.16.
4.9 Remove the protective tape on the lens and clean the inside surface removing any residue from
tape. Mount the included foam tape on the forward curved edges of the lens with about half the
width of the tape extended over the edges.
Note:
Additional foam tape is supplied for fitting on the upper and lower surfaces of the lens, just aft of the
top and bottom lens opening, but this may be a tight fit. Consider cutting the foam strip in half for less bulk. If
you’re satisfied with the lens to skin seal without the foam, top & bottom, just omit it.
4
.10 Attach lens handle once more, directly on the lens front surface. Do not wrap tape around edges
of lens and keep tape at least ½ inch from the top and bottom edges.
Note:
If tape does not adhere to lens on this final install, you may need to use fresh piece of tape to improve
the gripping force.
14
Properly seated
Lens and retainer
