Copilot Door Initial Fit

I made a tool to help scribe a trim line on the door flange. This was close to the scribe line in some areas but significantly different in others.

The guide on the tool follows the edge of the door opening and a sharpie in the hole marks the door flange on the outside.

I then removed most of the flange, leaving tabs for clecos in four locations. I then worked around the door, trimming close to the line and slowly approaching the edge of the opening. I beveled the inside edge as I went, allowing me to check the fit before removing more from the edge. Once I was close, I removed the tabs and fit the door into the intended position (the door drops about 1/8″ of an inch so that the top of the door is flush with the top of the cabin top exterior).

The process was slow, but it wasn’t nearly as bad as I had anticipated. The door sits reasonably flush with the cabin top in all areas and I’m quite happy with how it came out. That may change with hinges and the seal, but so far so good.