Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
7
Cutting the Lens Opening …
continued
Note:
We recommend using a power abrasive cutting wheel or vibrating blade to make the initial cut. Pilot
holes and a hack saw blade will also work, if you have the patience. We don’t recommend using tin snips as
these may leave kinks in the aluminum.
Warning:
To avoid hand abrasions, don’t leave burrs on the
edges of the opening. Your hands will be in and out of this
opening many times. Consider using masking tape on the edges
to protect your hands.
2. Mounting the Lens Retainers
2.1 Re-attach the lens (T1) template and locate the upper
lens retainer (marked with a “T”) on the skin just above
the opening (the upper retainer has an internal radius
on each end to position the lens). The template will show
the proper retainer location and orientation. Just locate
the retainer within the outline on the template and
clamp it to the skin with “C” clamps or another secure
clamping device (photo 5).
Caution:
the retainer will be used to spot drill the attach holes for mounting the retainer. Be sure the retainer
is properly located on the template with the milled “pocket” facing up and facing the opening (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 the retainer is tight and will not move out of position when drilling the holes.
2.2
Use the included #44 drill to drill four holes in the skin using the retainer holes as guides (photo 6).
Caution:
Use extra care to keep the drill perpendicular to the holes in the retainer. Do not “wiggle” the drill.
The retainer holes are threaded and a misaligned drill will damage the threads (photo 6).
2.3 Use the above procedure to locate and drill the bottom retainer mounting holes below the lens
opening. The bottom retainer is milled without the radii but is mounted exactly as above with
milled side out and facing the opening. The edge of the the bottom 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.
2.4
Remove the retainers and lens opening template. Enlarge all 8 holes with a 1/8 inch drill and deburr the
holes. Finish and deburr opening with files or other finishing tools until edges are smooth and burr free.
Take care not to mar or abrade the leading edge surface, especially if the aircraft is finished.
2.5 Apply masking tape to the edge of the opening to protect your hands and the acrylic lens.
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