Science

 Beams

Measure 26" from bottom of beam and mark the center. Form a block of 2x4 to fit inside the beam. Drill a 3/8" hole in each beam and block.  Counter sink the hole in the back of the wood block deep enough for a 3/8" bolt head to be flush. Attach the block to the back of the beam with micro-glass and Use structural adhesive to glass the bolt in place.

Line beams up 1/2" from the door frame. Cut and form areas around the door pins and conture of the fuselage. Fill beams with insulation foam to sound proof. After cured cut, sand and form foam to fit 1/4" inside the beam as room for the epoxy.

Apply micro-glass to the foam on beam and the inside skin of door frame and install beam. Let cure. Cut the fuselage out around the beam. Apply 3 bid to edge of beam and fuselage.  

Gas Spring

Measure 26" from the bottom of the structural beam and mark the corner. Sand a 2" area around the mark. Manufacture a hard point out of aluminum that will conform to the shape of the beam. Attach the hard point with micro-glass at a 45 degree angle. Drill a hole through the center of the hard point at a 45 degree angle to the beam. Tap the hole to fit the gas shock anchor. Screw anchor in place. Attach the gas shock anchor mount to the door so the top screw is just above the door pin. The vertical face of the plate must face the inside of the door. Attach the anchor and the gas shock.

Window

lPlace door on the aircraft making sure it is centered and level with duct tape and mixing sticks. Using a chalk line snap a line from the back of the rear window to the top corner of the windshield. Place window on the door and outline it. Remove window and mark a line 3/8" inside the outline on the door. Cut the window out with a hacksaw blade on the inside line. Sand edge smooth and strait. Bevel the outer edge of the window with a file or a sanding block till the window fits from the inside flush to the outer door skin. Sand the inside of the door skin and ½" on inside of window.  

lMask the window on each side leaving the beveled edge on the outside and the ½" sanded area on the inside exposed. Mix EZ poxy and flox and put a bead on the inside of the door skin. Place window against the inside of the door skin and center. Clamp and tape in-place. Lay 3 bid on the inside window edge, cover with peel ply and let cure.

Hinges 

Attach hinges to the door. Center the hinges to the hinge mount. Clamp or glue in place. Drill 4 holes through the hinge and the hinge mount. Tap the holes while hinge is still clamped and bolt in place with 3/16" machine screws. Install door and lock in place. Repeat the procedure for the side of the hinge that bolts to the by drilling though the hinge and roof from the outside.

 

Door Pins

lLocate the pre marked section of the door for the latch. Place the latch base on the marks and trace around it. Drill a hole though the inner skin of the door for the latch handle bushing with a 3/4 wood bit. Drill through the center of the first hole with a 3/8" bit for the rod. Assemble the latch mechanism with flush rivets. Glue and rivet latch plate on the inside of the door with latch bushing and rod in place with structural adhesive.

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lAttach rods to center cam. Line up the rods with the pre marked locations. Drill a holes through the raised door frame in line with the angle of the rods. Sand the outside of the rod guides and glue in place with structural adhesive. Grease the rod tips and assemble the complete door latch system and turn handle to locked position. Let cure. Cut off the end of the guide smooth to the door edge. Attach the aluminum stop to the upper pin rod. Mark the desired location of the lock.

 

Door Installation

Insert the door and lock pins in place with handle. Adjust the outside of the door so the edges are smooth with the body. Wedge paint stir sticks from the inside and outside till the door fits. Some warping may have occured so it might not be possible to adjust every part to fit. Grease the pins. Sand the outside of the cylinders and slide them onto the pins.   

 

lGlass the cylinders in place with Structural adhesive and caboslie. Place peel ply over the adhesive to keep it in place. Let cure. While the door is still in place and locked complete the needed body  work to the fuselage and door. 

lDuct Tape the high spost along the door and fuselage edge. Fill and sand all low spots till the door and fuselage edges are even. Remove door and cut the end of each cylinder to fit the angle of the door.

Lock

Attach the aluminum stop to the upper pin rod. Mark the desired location of the lock. Remmember that it must line up with the upper rod. Drill a hole through the door the size of the lock cylinder. Dissasemble the lock. Apply structural adhesive to ouside of cylinder and slide the cylinder through the hole from the outside of the door. Reassemble the lock. 

  

 

lDrill a 1/8" hole through the upper rod where the lock latch is located in lock possition. Tap the hole and install a machine screw through the hole long enough for the latch to strike.

Safety Lock

lSand the back of the safety lock bracket.  Center the bracket so the lock pin strikes the front of the lock stop when the door latch is in the closed possition.   Attach it to the inside of door skin with structural adhesive and rivets. Make a slot for the external lever by drilling through the door at the top and bottom then cutting the slot. Assemble lock.

  

lPanel

lPlace panel on in inside of the door. Maker the location of desired attachment points. Sand the edge of the door where brackets are to be attached. Glue and rivet brackets in place. Center panel over brackets and drill a 3/16" hole through the panel and brackets. Rivet 3/16" nut plates to the brackets.

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lTape the handle bump with duct tape. Cover the tape with micro-glass and 3 bid. Remove the mold and sand the cup into a round shape. Sand, fill and prime. Cut 1" off the top of the panel handle bump. Install panel and handle to check for clearance when handle is in open and closed possition. Adjust the cut till the panel does not interfear. Remove panel and place cup on bump. Drill holes around the perimiter of the cup through the panel. Install nut plates on the panel. Mark the inside of the cup where the lip of the bump meets it. Cut a slot the distance of the travel of the handle.