Landing light cover

[runwayrex]

To get the len’s outside dimensions, I tried laying the Lexan over the area and used a fine tipped marker to trace the outline. I didn’t have success with that method. Next, I removed the wingtip and got the lens to fit it perfectly, with plenty of Lexan to trim on the leading edge side. But it didn’t match the contour of the leading edge. I’m hoping I don’t have to buy a case of these lenses to get two that fit right! Any tips on all this?
Rex in Michigan
SS7 / 912 iS

[efwd]

While cutting the top and bottom edges of the plexi-glass I made a mark the best I could to reflect where the trimming needed to be made. I trimmed it shy of the marks. I used a belt sander to work the margins of the plexi-glass until all three sides matched the recess of the wingtip. That left the edge that meets up with the wing and I did the same with that side. The lenses do have a top and bottom so you have to make sure you have the upper and bottom camber matching. It is subtle, so much so that someone could make the argument that the cambers are equal when it comes to the lens. I don't believe they are.