Match-Drill 7/16 into the "walls" of the door using the holes in the pin blocks as drill guides. Remove the fwd and aft pin blocks.
45-13, Step 4
Attach the Latch Mechanism to the C-1002-R. Operate the latch mechanism so as to cause the Rack Trimmings to extend fore and aft from the latch mechanism and lightly contact the walls of the latch pocket. Mark the walls of the latch pocket around the ends of the rack trimmings. Retract the rack trimmings and remove the latch mechanism from the door. Drill 1/2 inch diameter (minimum) holes in the walls of the latch pocket. Temporarily re-attach the latch mechanism to the door and operate the latch mechanism. Check that the holes in the walls of the latch pocket will dear the ends of the rack trimmings. Enlarge the holes in the walls of the latch pocket if/as required to allow the ends of the rack trimmings to pass through with clearance of 1/16 to 1/8. Remove the latch mechanism and replace the rack trimmings with the Handle Racks. Because of the size of the latch pocket in the door and the length of the handle racks, the latch mechanism must be assembled "in-position" in the latch pocket.
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Remove the Van’s UHMW blocks. Starting on the aft pin block open the 7/16" holes in the fiberglass door corners with a step drill to 11/16" or larger to accommodate the new pin blocks. The door pin blocks in the kit are a little oversized to fit the various built doors. After sanding the pin blocks to fit in the area, push it onto the 7/16" pushrod. Make sure all sides fit in the door for better sealing. Clamp the block in place and match drill #12 though door skins into the blocks. The blocks come counter-bored for the MS21042-3 nuts. Remove the Delrin pin blocks for the next steps.
