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Builder:
  David Macdonald
Location:
  Sugar Land, TX - USA
Aircraft:
  RV-10
Total Build Hours:
  1256
Web Site:
  http://www.mykitlog.com/DaveMacdonal/

Date:  07-12-2017
Number of Hours:  5.50
Short Description:  Door Latches

Continued to work on the door latches.

Assembled the inside handle/latch. Found that the slot in the handle shaft was slightly too small to allow the roll pin to easily slide down the slot to allow the handle lever C-1008 to move the roll pin against the spring V-197. Opened up the slot slightly with fine files. Also found that the slot at the end of the handle for the handle lever was too small to allow the lever to slide up/down in the end of the handle. Opened the slot slightly with fine files. Also found that the handle lever was slightly bent, so straightened it using the vice and hammer. Once everything fit properly, was able to assemble the handle, lever, spring and slide per the Van's drawings. Used small vice grips to compress the roll pin (lubed with WD-40) and insert it.

Assembled the low profile gear/latch mechanism for both doors. The gear wouldn't fit into the inner ring without slightly reducing the gear edge circumference and removing a slight burr on the inside of the inner ring. Once the gear fit in the inner ring, I found that the powder coating on the inside handle shaft extended about 1/16" too far down the shaft, which prevented the gear from going far enough down the shaft to allow install of the roll pin. Used a razor knife to score the paint and then trim it back by 1/16", then finished with 200 grit sand paper to smooth. Then able to assemble the gear and inner ring to the handle assembly per the Aerosport handle instructions.

Set the assembly into the latch pocket on the left door, with one set of gear racks sitting on the inner face of the door. Installed longer screws temporarily to hold the latch assembly in place. Lined up the gear racks so they were parallel with the door bottom (using a ruler to measure each end to make them even) and marked the top and bottom of each rack on the door inner face next to the latch pocket. Remove the gear racks and placed the outer guide back into the pocket with the screws. Then extended the height of the rack to the edge of
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