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Fresh Aero FlightLights

TLR Light Lens Mounting Kit

For Sonex Aircraft

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Study and save this manual

Read this entire manual before starting your lens installation and refer to it during

                       installation. Make sure you understand the instructions and safety precautions in
                       this manual. Failure to follow all the instructions in this manual can cause personal
                       injury. Keep this manual and your invoice in a safe place for future reference. Do
                       not use this product if you do not understand all the instructions and safety
                       precautions in this manual. If this product is used without observing the information

given under this symbol, injury may result.

Fresh Aero TLR Light Lens Mounting Safety Warnings and Precautions

Warning: Always adhere to the following safety precautions when using this product.

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Always keep the work area clean. Cluttered areas invite accidents and possible injuries.

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Stay alert and concentrate on safety.

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Never perform aircraft maintenance if under the influence of alcohol or drugs. Read

      warning labels on prescriptions you are taking to determine if your judgment or reflexes

will be impaired while taking these drugs.

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Always maintain proper footing  and balance during the lens install process. Ask for help if
necessary. Awkward positions and/or improper bending can cause falls, personal injury and
equipment damage.

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Always locate aircraft on a level surface and chock aircraft  tires to prevent movement.

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Use proper safety equipment and precautions when cutting the lens mounting hole in the
the wing(s). Hole will have sharp edges after cutting so be sure to de burr the edge of the
hole completely to avoid abrading your hands on the edge.

Warning:

The warnings, precautions and instructions discussed in this manual cannot cover all

possible conditions and situations that may occur. It must be understood by the operator that
common sense and caution are factors that cannot be built into this mounting kit and must be
supplied by the person or persons using this product.

If you have questions regarding the installation or operation of this TLR Light Lens Mounting Kit
or  just  need  another  manual,  please  contact  Fresh  Aero  at  the  contact  numbers  or  e-mail
address  on  the  last  page  of  this  manual.  Our  manuals  are  also  on  our  web  site,
www.freshaero.com, in PDF format.

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Summary of Contents for FRESH AERO

Page 1: ...FRESH AERO FlightLights TLR Light Lens Mounting Kit For Sonex Aircraft The Steelebrook Group Where Imagination Meets Innovation User Manual...

Page 2: ...plates will guide you easily through the entire leading edge cut out and lens install process The lens kits include everything you ll need to mount the lens the lens retainers drill screws and foam se...

Page 3: ...g to determine if your judgment or reflexes will be impaired while taking these drugs n Always maintain proper footing and balance during the lens install process Ask for help if necessary Awkward pos...

Page 4: ...original purchaser that this product is free from defects in materials and workmanship for the period of 3 years from the date of purchase This warranty does not apply to damage due directly or indire...

Page 5: ...and skin bending moments at the outboard locations The Sonex OneX may be an exception to this recommendation as the section inboard of the wing fold is a separate skin section and is inherently rigid...

Page 6: ...seam at the spar The actual dimension isn t critical but the distance at each side must be equal This ensures that the lens opening is square with the leading edge Very Important Important If you are...

Page 7: ...ing photo 5 The edge of the the retainer must be parallel to the opening edge and 3 8 inch 9 5 mm from the lens opening It s very important to maintain the spacing and parallelism Also confirm that th...

Page 8: ...l be used multiple times during the fitting process Hint Use an additional strip of tape on the inside of the handle sticky side to sticky side to prevent your hands from sticking to the tape photo 7...

Page 9: ...roper acrylic plastic cutting and stock removal procedures when trimming lens Do not use snips or any other tool that might crack or damage the acrylic Also during the lens trimming process it s bette...

Page 10: ...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...

Page 11: ...iner 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 betw...

Page 12: ...emoving 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 installa...

Page 13: ...four screws 4 14 Tighten the four upper retainer screws Caution To prevent stripping the retainer threads do not over tighten the retainer screws These screws should not back out To prevent this just...

Page 14: ...ix Use the following templates to facilitate your wing leading edge lens installation procedure The procedure steps will identify the correct template to use and how to apply the templates Lens Openin...

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