Regarding the doors, I've been working on getting the seals to fit properly. Once I felt they were about right I worked on the spacing between the doors and the cabin top. Still lots of work to do but here is what I have so far.
|Passenger side door gap after inserting the foam spacer (seal), applying micro liberally on both sides of the foam, and then sanding the micro and foam spacer down to create an even transition. In this picture the foam has not yet been removed.
|Side view of same door as picture above.
|In this picture you can see the seam between the cabin top and the fuselage. I sanded and then filled the small gap with micro/epoxy filler.
|The door gap came out pretty nice by using some 1/8" rubber gasket material. If I were going to do it again I don't think I would use the same stuff since it was a real bugger to remove. The sticky side was up against the door and the plain rubber side was against the cabin top. Turns out that epoxy loves that plain rubber and stuck like crazy. I had to actually sand the gasket material off of the cabin side.