SECTION 45: CABIN DOORS & TRANSPARENCIES

Build Instruction Updates

• 03/10/05 45_10.pdf

Check for more recent updates here

General

• For door options see the page Door Looks / Hinges / Handles / Seals.
• If you are installing the PlaneAround third latch, consider installing the gearbox before bonding the inner and outer door shell, see this FB post
• Do not clean adhesive residue off the windows with anything but mineral spirits. Do not clean with concentrated alcohol. The exact instructions can be found here.
• Door fit: See this VAF Thread
  and this FB post
  and this FB post
  and this FB post
  and this FB post
• Epoxy to use: See this FB Thread 3/2024
• After trimming the windows, you might need to renew the protective wrap, consider using collision wrap.

45-02

• The holes in the two door halves don't align, just use the ones that do align, see also this FB thread 4/2024.

45-06

• A bolt is used as hinge pin. Consider grinding down the head a bit if it interferes with the cabin pocket.
• A group of builders are working on a hinge cover, see OnShape CAD project, check fit using this 1:1 print pdf file
• The plans provide instructions for fitting the hinges to the LHS door, and Step 3 provides the positions for the WD-1019-L and WD-1019-R hinges. The plans then instruct the builder to 'repeat this step for the right side door hinges'. Note: the WD-1019-L hinge must be placed Forward side, and the WD-1019-R hinge must be placed Aft side of the doors, not Left and Right as the part naming would suggest.
  
  See also section 4:
  

45-08

• Silpruf Method
  • Silpruf @ Amazon
  • 5-part instructional video
  • See also Dan H's write-up of the above Silpruf Method
  • See also this Glastar article.
  • Notes
    • This method requires drilling holes along the edges of the windows. If your inside is in a finished state, this will cause patching / touch-ups after the window installation.
    • The video recommends 6 inch sanding discs which aren't readily available. 4 1/2” flap sander disks from Harbor Freight work as well.
• Sikaflex
  • General Sikaflex instructions
  • Yannick B's write-up on using Sikaflex for the windows
    Pictures are here.
  • This thread says one needs 4 tubes of Sika 295: FB thread
• A good read on window attachment is this VAF thread
• June 2023 FB thread
• Be diligent with the window attachment, this VAF thread talks about a window which popped out during flight: this happens
• Feb 2024 FB thread
• Aug 2024 FB thread

45-19

• Windscreen base fairing lay-up
  Windshield_to_Fuse_Transition_Steps.pdf
  See also Van's video for the RV14.