I started off today using my laser crosshairs to verify the vertical cut lines on the leading edge light pockets (I did this on the right side as well).

I started on the left side by making up a tape outline of the lens cutout.  I then placed lens blank #1 over the tape outline, traced it onto the lens with a non-permanent whiteboard marker and cut the lens to the shape.

I discovered that, unfortunately, if you don’t thoroughly tape up the lens that you may get a small crack as I did on the left (inboard) side of this lens.

So lens #2 got all sorts of taped up on both the interior and exterior surfaces before I started cutting with the Fein saw (pic 1), and this time it cut without any unwanted cracks (pic 2).  This is exactly why I made at least 2 lenses for each side!

Here we have uncracked lens #2 with the tape peeled off (pic 1), and back in place for a test fit (pic 2).  Then, after I retaped the lens and cleaned up the edges, I used this lens to do a final outline on the wing leading edge to cut out the perimeter of the light pocket.

Here we have the perimeter of the light pocket marked for cutout (pic 1) and after cutout doing a quick check fit of the taped lens (pic 2).  Not surprisingly a bit more refinement will be required on the perimeter cut for the lens to fit just right.

And here we have a wider angle shot of the left wing light pocket —with all the protective tape removed— initial cut on the leading edge.

I then did pretty much the same thing on the right side with both lenses.  Here we have lens #1 taped in place (pic 1) and the initial perimeter cut made on the lens (pic 2).  I’ll note that I made a copy of the lens outline of the left side, flipped it and applied it to the right side… so both sides’ lens size and shape are very close to each other.

I then cut out lens #2 and set it back in place after the final cuts (pic 1), and then removed it to show the green lens template (that I copied/mirrored from the left wing) underneath (pic 2).  [Note: in my haste to get this done, I labeled lens #2: “Lens #1 red” and lens #1: “Lens #2 blue” to denote the color of ink I was using to outline each lens on the leading edge to assess my final cut line].

I then used the Fein saw to cut out the lens perimeter on the right wing leading edge for the light pocket.

I then test fit both lenses back in the right wing leading edge light pocket cutout.

And just as the left wing, here we have all the protective tape pulled and the right wing leading edge light pocket ready for further install tasks.

My primary goal for tomorrow will be to convert the splashes by adding tape to the insides of those and using them to layup 3-ply carbon fiber flanges that will go just inside the wing skin and provide a mounting surface to secure the lenses in place on the wings… nice and flush with the wing surface.

To be clear: I’m knocking out these wing leading edge lights now to clean up all the collateral install “damage” so that these light installs will be complete and clean prior to primer and paint.