Speaking of landing light cutouts...

[FlyGuy65]

Any consensus on best techniques to actually cut the leading edge? RV-7, leading edge riveted together but not riveted to spar. 2003 era Duckworks kit.

Options readily available are Weiss snips, hacksaw, jigsaw, or Dremel with ceramic cutting disk.

I've read the hardest part is actually making that first cut....

Thanks!

[bobnoffs]

i have made many cutouts [including 2 land light] and never had a bad outcome with the dremel tool. i have always protected the area around the cutout but never had the tool slip or jump. measure twice cut once really applies though.

[Kyle Boatright]

A dremel or other rotary tool is the most common choice. For me, a jigsaw is much more controllable, but you need to find an extremely fine toothed blade to use. I'm not sure they make something fine enough for the LE skins.

[KatanaPilot]

The technique that worked for me on an RV-7 and RV-10 - layout the pattern on the leading edge. Figure the centerpoint of the radius at the corners and drill a small (#40) pilot hole there. You can use a hole saw of the appropriate diameter or an annular cutter (my preference if you have one) and make the four corner cuts. Use a Dremel or similar tool with the small thickness disc and cut the straight lines between the holes. Use a file or pneumatic tool(s) to clean up the lines up to the pattern.

Good to stay inside all of the lines of course, to give some margin for error and clean up.

The lens is slightly oversized and will cover small misses.

[John Tierney]

I started with a unibit in 4 corners then used tin snips, sanding drums, files, etc. Just make sure you get the top and bottom correct. If you take a close look at the Van's RV-9A demonstator, they had to fabricate a filler piece because they cut it wrong the first time.

[robertahegy]

I taped off the area with masking tape and penciled in the cutout shape. Then I used a Dremel with a cutoff wheel staying away from the lines by about 1/8 inch, a bit more in the corners. Once the major cut was made and leading edge portion removed, I finished the opening using Dremel sanding drums of 1/2" and 1/4" sizes in course and then finer grits. The finished opening was then buffed with scotchbrite. This was a quickbuild wing.

Roberta

[Alchemist]

fast forward half way through and you can see where I start cutting.

https://www.youtube.com/watch?v=y2cWXNO40MU&t=3s

[unitink72]

I have an air powered body saw, and it worked super slick for this purpose. Its just like a tiny reciprocating saw whose blade is much smaller and recips at a much faster rate.

Search for CP 7900

[N941WR]

Originally Posted by unitink72

I have an air powered body saw, and it worked super slick for this purpose. Its just like a tiny reciprocating saw whose blade is much smaller and recips at a much faster rate.

Search for CP 7900

Exactly what I used.

Tapped off the area, drew on the tape with a Sharpe, drilled a hole near the edge, used a body saw to cut it out, and finished the opening with a file.

[Desert Rat]

I used weiss snips for mine and it worked out fine. Stayed off the line by about 1/8" or so, then finished up to the line with a vixen file.