Door Seal Flange

As many others have done, I used lengths of McMaster door seals as sacrificial molds for building up the door flange.

I used a syringe to apply a flox/cabosil mix to the seal channel as I worked around the opening of each door.

I then secured the door seals with tape to ensure that they were fully seated on the door flange.

I used a piece of wood at the bottom of the door sill to flatten the inside flange of the seal channel against the sill.

The end result is an even 1/4″ edge around the door opening. I’ll clean this up when finishing the cabin top.