Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
6
Cutting the Lens Opening …
continued
Note:
A good way to determine the apex of the the leading
edge is to look down the leading edge (like sighting a gun)
and look for the forward most point. Draw the horizontal lines
at this point.
Note:
if the aircraft is painted, just apply a short strip of
painter’s tape to the leading edge at both sides of the
template and draw the horizontal line on the tape.
1.2 Align the horizontal apex guide line on the template
with the apex and align the template vertical rivet
guide lines with the wing rivet lines.
1.3 Use masking tape to secure the template (photo 1).
1.4 Measure from the top horizontal line of the template
(at both sides) back to the the leading edge 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 using the Fresh Aero TLR Light and
brackets, they are designed to center the light between the rib
rivet holes and will align with the above template location
correctly. If you’re using other lighting, you need to confirm
that the lens opening will align correctly with the lights you
use. If not, move the template to correspond with the light
centerline.
1.5 Use a felt tip marker to trace a line on leading edge
of the wing using the lens opening on the template as
a guide (photo 1).
1.6 Remove the template and cut out the lens opening on
the wing with your selected tool (photo 2). Cut
slightly away from the line to allow room for error.
Finesse the opening with files or other hand tools to
achieve the final dimension. Deburr and smooth edge
of opening (photo 3).
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