Since my last post I have completed the following:
- Both doors fitted to the fuselage
- Interior and low profile exterior handles installed and functioning
- Center latch block installed (still need to install the brace that attaches to the fuselage)
- Installed nut plates in the door side of the hinges so that I don't need to have nuts and washers on the back side. This will allow me to cover that area with fiberglass ensuring a seamless door seal.
- Door strut brackets fitted to the cabin top.
- LOTS AND LOTS of fiberglass work on the door frame to make the McMaster-Carr door seals attach properly.
- Lots of time spent preping the cabin top for installation. This includes a little more dimpling, some deburring, coutersinking, rivet backing strip fabrication, cabin vent holes cut and flanges drilled, and the list goes on.
|This is one of the hinges that I installed nut plates on. This will allow me to cover the hinge pocket so that the door seals have a nice smooth surface on the door to seal against.|
|Preparing the door strut and attach points. In this picture you can see the two small aluminum inserts I turned on the lathe to act as spacers for the strut bracket.|
|Working on the lathe to create the spacers in the picture above. Washers would have worked here but this spacer was much more fun to create.|
|Here it is with everything loosely connected. Next up it gets drilled and bolted to the fuselage and doors.|
|These are the attach points for the door struts. I used a little bit of epoxy with flox to even out and make a nice seat bed for both brackets.|
|The cabin top console with the vent holes drilled, the lighting holes drilled, and the nut plates installed for the two removable covers. The cabin top is not attached yet.|
|This is the area where you have to trim the console to fit the strut brackets. You will also notice that there is quit a gap between the console and the cabin top. This will require more fiberglass work.|
|The front portion of the console with the center support bar holes revealed.|
|This picture shows the profile that I created for the door seals. There is still a bit more work to do on them but I am really happy with the way this all came together so far.|
|Rear overhead vent holes drilled and the flanges cleco'd on. I wont rivet these in place until the top skin is riveted on. With these vents attached I wouldn't be able to buck the rivets above the vents.|