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I am using McMaster door seals which require that the hinge attachment areas in the door be covered to complete the seal. I didn’t like the idea of burying nutplates here (as used by one after-market option) but I liked… Read More »Door Hinge Pockets
I am installing carbon fiber door sill caps from Aerosport Products. These are lightweight and should help protect the edge of the door sill. I aligned the doors and PlaneAround 3rd Latch with this in mind as this adds about… Read More »Carbon Fiber Door Sill Caps/Third Latch
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… Read More »Door Seal Flange
I am installing the Van’s door latch indicator system to provide positive verification that the doors are correctly latched when closed. In retrospect, it would have made more sense to purchase the sensors and magnets separately as I did not… Read More »Door Pin Sensors
I upgraded to the Van’s 600N struts (C-1016HD) when I ordered my finish kit. I am also using the PlaneAround door strut attach brackets. These have an anodized black finish and look much nicer than the stock brackets. I 3d… Read More »Door Struts
After completing the copilot door, the process of installing the seal and latch on the pilot side door went much more quickly I used the same technique and bonded the pin blocks into place with epoxy before match-drilling the holes… Read More »Pilot Door
I am installing door seals from McMaster-Carr (part number 1120A411), the PlaneAround third latch mechanism, and the PlaneAround angled door pins. This log entry details the prep work and fitting of these parts. I started by creating a 1/4″ gap… Read More »Door Seals and Latches
After several dusty sessions of trimming, sanding, and shaping, the pilot side door now fits in the opening.
While the pilot door was curing, I started on the copilot door hinges. The hinge pins are made by removing the threaded portion of AN3-21A bolts. I also choose to round the hex head for a cleaner look. I then… Read More »Copilot Door Hinges
The copilot door fitting is going well so Amber and I decided to proceed with bonding the pilot door. We followed the same procedure as last time so there isn’t much more to say about it.