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Bob Leffler's RV-10
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Date:  9-12-2010
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Removing flush handles and lowering door hinges

The door hinges stood a little proud in towards the center of the cabin cover. I used a routed and trimmed the hinge opening a bit. The outside edge was level, but had to take off about 1/8" towards the center. My router made this task pretty easy. I then had to use a dremel tool to get the back corners, since my router bit had a 3/4" radius.

After working with the flush handles for the last week or so, and attempting to integrate them with Sean's safety latch, I decided to take the flush handles out. Fortunately, I only cut holes on the right door.

Technically, there is nothing wrong with the iflyrv10.com flush handles. The instructions are not well written. I found out too late that if you follow the instruction precisely, you'll mount the handle a little too low. This started a myriad of creative engineering that started to snowball other issues. Being somewhat of a perfectionist when it comes to the RV-10, I didn't like how things were going.

I decided to go back to standard Van's handles, with Sean's 180 degree safety latch. This meant that I had to patch the holes I put in the right door. With Brad's assistance, I patched the outside hole for the handles. There are several plys of fiberglass in the hole and three more layers on the inside. We'll see tomorrow how much more work I"ll have on the outside. I suspect I'll need to add a little micro to smooth things out.
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Routed out the hings area

Routed out the hings area

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Fiberglass patch for flush handle

Fiberglass patch for flush handle

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