Brief Description: Gas Strut Attach Doublers and Prepped Right Door
45-03, Steps 1, 2, & 3 Right Door
Cleco the C-1002A-L Door Outer Shell to the C-1002B-L Door Inner Shell using the four #40 holes in the window flange of the door inner shell.
Cleco the C-1002A-L Door Outer Shell C-1002B-L Door Inner Shell into the fuselage using the forward and aft index holes. Verify that there is a constant 1/16 to 1/8 inch gap between the C-1002B-L Door Inner Shell and the return flange of the C-1001 Cabin Cover.
45-04, Steps 6 & 7
Position one of the C-1 002C Gas Strut Attach Doublers on the bag side surface of the C-1 002B-L Door Inner Shell. The gas strut attach doubler centers on the width of the aft hinge pocket molded into the door inner shell. The shape of the gas strut attach doubler can be adjusted as required to achieve a good fit to the door inner shell. The fit need not be perfect because the glue used to attach the gas strut attach doubler to the door inner shell will easily fill any gaps of up to 1/16 inch. Match-Drill #30 and deco the gas strut attach doubler to the door inner shell. Remove the gas strut attach doubler and deburr holes. Repeat this step for the right side door.
Mix some epoxy and thicken it with cab-o-sil to the point that il will not pour out of the mixing cup. A total mixture quantily of about 2 fluid ounces will be required. Use 80 grit sandpaper 10 roughen the mating surfaces of the C-1 002B-L & R Door Inner Shells and C-1002C gas strut attach doublers. Apply a 1/16 inch thick layer of thickened epoxy 10 each gas strut attach doubler and deco each one to the appropriate door inner shell. Use two clecos for each gas strut attach doubler inserted through the two holes on the part centerline. Install the decos from the tool side of the door inner shells. Use hand pressure to seat the gas strut attach doublers to the door inner shells and to squeeze out any excess epoxy which should be removed. After the epoxy has cured re-drill the holes to #30 and install rivets.
