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Hi
Attached are a couple of photos of my installation.
I tried MULTIPLE times to mold lexan over a mold of the leading edge I had created. I could never seem to get it to work without bubbling. I finally sent my molds to Aircraft Windshield Company, 10871 Kyle Street, Los Alamitos, Ca 90720 (562) 430-8108 & they were able to get an acceptable lens without bubbling.
I had best success with a belt sander to form & shape - I always seemed to break the lens with what ever saw I tried to use. As you can see, I basically formed the shape flush, and used leading edge tape to seal.
I shaped a pocket of prepreg behind on the sides & back of the light & reinforced to retain strength. So far so good (500+ flight hours so far).
Good Luck!
Doug Owen
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