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Larry Winger's 601XL Project
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Date: 11-2-2007
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Number of Hours: 0.00
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Manual Reference:
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Brief Description: Process for making landing light lens
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As described previously, I made my form from two unused nosr ribs form blocks. It could just as easily have been from actual nose ribs. The important thing is to duplicate the shape of the leading edge of the wing. I found great success by heating the Plexiglass (acrylic) in the oven at 350 degrees for about 4 or 5 minutes. You'll know it is ready when the edges get a bit curled or wavy. Before putting in in the oven, I had put a small black mark on each edge where it should contact the more foreward part of the leading edge form. As soon as it was draped over the form, I used a large sheet of felt to apply enough pressure to keep the edges from curling. The cost of the materials, per lens, is less than $3.00. At that rate, I'll have no problem deciding to replace the lens when scratching becomes an issue. NOTE: At the time of installation, it is possible to get an even better fit that conforms perfectly to the inside surface of the leading edge. I wrapped paper around the shaft of two thin "chip chasers" (to prevent scratching), slid them in top and bottom, hooking the back edge of the plexiglass. Then I used the heat gun set at 850 degrees to barely soften the leading edge of the plexiglass. Without waiting too long, I put down the heat gun and pulled gently on the two chip chasers, snugging the plexiglass against the front edge. Perfect results!
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Form with pliable Plexiglass
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