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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.
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… Read More »Copilot Door Initial Fit
I had previously fitted and tested the door hardware and we were ready to bond the door halves. I decided to bond and fit the copilot door first to make sure there were no surprises before bonding the other door.… Read More »Copilot Door Bonding
I had a few final things left to do before bonding the door halves. First up was preparing the stiffeners for the door struts. I chose to alodine these for corrosion resistance. This gave me a raw metal surface to… Read More »Door Bonding Prep