Brad assisted me today with trimming the right door. I think we are at the 99% done. I won't trim again until I get the rain gutter built back up to 1/4" and the McMaster Carr door seal installed.
45-06, Steps 1, 2, & 3
Place the C-1002-R Door on the fuselage and hold it in place with duct tape.
Working from inside the cabin, match-drill #12 one of the outboard holes in each of the WD-1019 Door Hinges. Temporarily insta ll a screw/washer/nut through the door hinge and C-1002-R Door. Match-Drill #12 the remaining outboard hole in each door hinge and install screw/washer/nut.
Un-tape the C-1002-R Door, swing it open and match-drill #12 the remaining 2 holes in each WD-1019 Door Hinge. Machine countersink the outside surface of the door at the four open holes. Install screw/washer/nuts in countersunk holes. Remove screwlwasher/nuts from the holes not yet countersunk and countersink the holes. Install screwlwasher/nuts in the holes. Close the door and see if it distorts. If the door wants to ride too low relative to the cabin cover shim between the inside surface of the door and WD-1019 Door Hinges.
45-16, Step 1
Position the WD-1023 Gas Strut Attach Bracket on the C-1001 Cabin Cover. The gas strut attach bracket inboard/outboard position is determined by the point of "best-fit" to the cabin cover. The gas strut attach bracket is centered fwdlaft on the door hinge. With the gas strut attach bracket held in place, match-drill #12 through the cabin cover using the holes in the gas strut attach bracket as drill guides. Install a temporary screwlwasher/nut in each hole as it is drilled to hold the gas strut attach bracket in position while the remaining holes are match-drilled. Remove the gas strut attach bracket and deburr the holes thai were just match-drilled. Machine countersink the holes in the cabin cover to fit the head of an AN509ยท10 screw.
I am using a custom bracket made by Sean Strasburg at planearound.com. It is a little lower to accomodate the McMaster Carr door seal.
