As many others have done, I used lengths of McMaster door seals as sacrificial molds for building up the door flange.
![](https://airplane.allanglen.com/wp-content/uploads/2024/02/pxl_20240203_201710220572686275618099380.jpg)
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I used a syringe to apply a flox/cabosil mix to the seal channel as I worked around the opening of each door.
![](https://airplane.allanglen.com/wp-content/uploads/2024/02/pxl_20240203_0232566381770474171217891361.jpg)
I then secured the door seals with tape to ensure that they were fully seated on the door flange.
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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.
![](https://airplane.allanglen.com/wp-content/uploads/2024/02/pxl_20240203_0308209294373677668595255903.jpg)
The end result is an even 1/4″ edge around the door opening. I’ll clean this up when finishing the cabin top.
![](https://airplane.allanglen.com/wp-content/uploads/2024/02/pxl_20240203_1856081464716853927472078851.jpg)
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