Landing Light 2

Once you've drilled the holes to locate the position of the landing light, it is time to assemble the mount.  The kit is universal to fit both the RV6 and RV7 wings, so you have to assemble one flange depending on width between ribs.  The plans have you measure this, but I went ahead and installed both pieces on the ribs and drew a line on the mount to locate the flange.  Once the position is located, you then drill, dimple, and rivet the bracket together.

With the mount all assembled and located in place, it comes time to shape the plexiglass.  I taped over both sides of the glass with painters tape to protect it from scratches (a very good idea).  I then centered the lens in the opening and traced the shape of the opening onto the tape.  Once the plexi was removed, I then traced another outline of the shape the recommended edge distance from the cutout.

I then used the belt sander and some finishing sandpaper to finish the edges.

To drill the lens attach holes, the instructions have you create a "tape handle".  Although it sounds very odd, it works quite well.  I had to buy special strapping tape to do this, as the regular tape I had kept ripping.  When drilling the holes, be sure to go very slow.  I have heard lots of people have trouble with cracking the plexi (from going too fast).  I went slow with a regular drill bit and did not seem to have any problems.

Once the holes are located (via a template), you obviously deburr and dimple the holes.  The plexiglass must be countersunk, as it cannot be dimpled.  Once the plexiglass is c-sunk, you install the backing plates with nutplates using double-sided tape.

Here is a shot with the mount installed with and without the plexiglass.  The picture makes it look distorted, but it actually fits very nice.