forecast=200,complete=true
I followed the Van’s fiberglass fairing how-to video series to bond the windscreen to the aluminum skin and build up the fairing. I started by marking the upper edge of the windshield fairing. I 3d printed a template with the… Read More »Windshield Fairing
I opted to use Cee Bailey windows when I ordered my finish kit. I have nothing to compare it to, but the overall fit of the Cee Bailey windshield was poor and required a lot of trimming. The lower left… Read More »Windshield Installed
I used the Silpruf method for installing the windows. I used Cee Bailey windows and black Silpruf SCS2000. I started by trimming the windows to a 5/32″ gap. The Cee Bailey windows fit well on the left side, but needed… Read More »Windows Installed
Finally. The doors feel like a neverending part of the project. After multiple iterations of micro and sanding, the doors smoothly transition to the cabin top. I gapped the doors to a gap of just under 1/8″. A lot of… Read More »Doors Complete
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