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Zenith CruZer & Sonex Logs
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Date:  4-2-2020
Number of Hours:  1.60
Manual Reference:  C75-NA-2
Brief Description:  Initial Drilling Right door gussets

First up was partial primer application on the left door frame. Can was sputtering so had to clean the nozzle; didn't want to do the entire piece because I wasn't hanging it and wanted to be able to hold it.

Next step was initial placement and trimming of the left, right, and lower door frame pieces. This was an easy task, but some ends took a few attempts to get just right. Fits better than the left!

Lastly, I taped all 3 pieces into place, then clamped the gussets into position such that all 4 gussets were even with the frame tubes. Pilot drilled all predrilled holes thru the gussets and into the door frame with #40 drill, then went and up-drilled to #30. These will eventually be #20.

Left the door installed, but checked for proper swing to make sure nothing was binding like it was on the left door.

Next step is to install the 4 corner braces after pilot drilling each one with 4 holes.
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taped in position; pieces trimmed

taped in position; pieces trimmed

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drilled & cleco'd

drilled & cleco'd

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