Fresh Aero FlightLights
TLR Light Lens Mounting Kit
For Sonex Aircraft
9
Fitting the Lens …
continued
3.8 Locate the Lens Trimming Template (T2) in the appendix. You will use the center section as the
trim guide. Draw a pencil line on the lens 5/8 inch from the top lens opening tracing and parallel
with the tracing (towards the top edge). Cut out the template section depicted by the red line and
align the upper red edge (labeled on template)
with the pencil line just drawn. Secure the cutout
to the lens with tape. The top line on the tem-
plate (with the radii) is the line you will use to
trim the upper edge of the lens.
3.9 Cut or grind the top edge of the lens to conform to
the above template top line including the radius
at both ends (photos 8, 9, 10, 11, 12). Provide 1/32
inch spacing between lens and radius on both
sides to allow for lens expansion.
Caution:
Use proper 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 better to trim
conservatively and then slowly remove access material
with subsequent adjustments.
Note:
Drawing D1 in the Appendix will help clarify the
following steps.
3.10 When the upper edge of the lens is trimmed
properly, mount the upper lens retainer to the
inside of the skin through the lens opening
using the drilled holes and the included ¼ inch
long 4-40 screws. The milled “pocket” must be
facing towards the opening and the skin. This
forms a pocket between the skin and retainer to
accept the lens. Gently tighten the screws.
3.11 Re-attach the tape handle as before and mount
the lens again. With this mounting, rotate the
lens bottom edge aft until the upper profiled edge
can be inserted in the milled pocket of the top
retainer. Confirm that the lens is centered using
the center marks and traced lines on the lens before moving to the next step.
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