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SECTION 45: CABIN DOORS & TRANSPARENCIES: Difference between revisions
Added door seal instructions.
(Added door seal instructions.) |
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* 03/10/05 [https://www.vansaircraft.com/wp-content/uploads/2005/03/45_10.pdf 45_10.pdf] | * 03/10/05 [https://www.vansaircraft.com/wp-content/uploads/2005/03/45_10.pdf 45_10.pdf] | ||
Check for more recent updates [https://www.vansaircraft.com/service-information-and-revisions/?aircraft=rv-10&doctype=revisions-changes&sort=date here] | Check for more recent updates [https://www.vansaircraft.com/service-information-and-revisions/?aircraft=rv-10&doctype=revisions-changes&sort=date here] | ||
* Important: if you are using the Planearound 180-degree cam AND the Aerosport low-profile exterior door handles, [https://img1.wsimg.com/blobby/go/85ec6025-f02d-4bd9-b354-d9bef14e3672/downloads/e338c50b-3a76-446a-920a-64b0f7271a21/Door%20Mechanism%20Installation%20Compilation%20Docume.pdf?ver=1738948265394 this guide] will save you many hours of frustration. | |||
=== Before You Start === | === Before You Start === | ||
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* If you are using a window install method that needs deeper window pockets, consider ordering four pieces of Polypropylene Rod, 1/4" Diameter, 8 Feet Long (McMaster part 8658K51) while ordering your door seal. You can temporarily fit these into the window openings as spacers to help build up epoxy around the windows to the proper depth as shown in this photo. | * If you are using a window install method that needs deeper window pockets, consider ordering four pieces of Polypropylene Rod, 1/4" Diameter, 8 Feet Long (McMaster part 8658K51) while ordering your door seal. You can temporarily fit these into the window openings as spacers to help build up epoxy around the windows to the proper depth as shown in this photo. | ||
[[File:2025-06-26 18.52.29.jpg|none|thumb|1/4" plastic spacers temporarily epoxied into window opening to make it easy to build up the epoxy around.]] | [[File:2025-06-26 18.52.29.jpg|none|thumb|1/4" plastic spacers temporarily epoxied into window opening to make it easy to build up the epoxy around.]] | ||
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* Epoxy to use: See this [https://www.facebook.com/groups/vansrv10/posts/7171726742948363 FB Thread 3/2024] | * Epoxy to use: See this [https://www.facebook.com/groups/vansrv10/posts/7171726742948363 FB Thread 3/2024] | ||
* After trimming the windows, you might need to renew the protective wrap, consider using [https://www.amazon.com/dp/B09GWCJYTV collision wrap]. | * After trimming the windows, you might need to renew the protective wrap, consider using [https://www.amazon.com/dp/B09GWCJYTV collision wrap]. | ||
* Important: if you are using the Planearound 180-degree cam AND the Aerosport low-profile exterior door handles, [https://img1.wsimg.com/blobby/go/85ec6025-f02d-4bd9-b354-d9bef14e3672/downloads/e338c50b-3a76-446a-920a-64b0f7271a21/Door%20Mechanism%20Installation%20Compilation%20Docume.pdf?ver=1738948265394 this guide] will save you many hours of frustration. | |||
* This is a [https://www.youtube.com/watch?v=FJXQlKcADOE pretty good video] showing the full door process. | |||
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* Step 1: Check the position of the strut versus the hinge. The innermost hole of the strut is about at the position where the hinge pin resides. If you mount the strut bracket too far outwards, the bracket for the strut on the door end cannot be placed above the window, it would overlap with the window.<br>If you are getting the Aerosport overhead panel, you need to match drill the door strut attach bracket to the canopy before attaching the overhead panel. It is necessary to notch the overhead panel for the bracket.<br>If you are getting the after-market PlaneAround DOOR STRUT ATTACH BRACKETS, do not match drill with a #12 bit since the holes are already threaded for 10-32 bolts. Consider match drilling with a #22 bit, then enlarging the hole to size #12. You may have to chase the bracket threads with a 10-32 tap if the #22 drill bit damaged them. | * Step 1: Check the position of the strut versus the hinge. The innermost hole of the strut is about at the position where the hinge pin resides. If you mount the strut bracket too far outwards, the bracket for the strut on the door end cannot be placed above the window, it would overlap with the window.<br>If you are getting the Aerosport overhead panel, you need to match drill the door strut attach bracket to the canopy before attaching the overhead panel. It is necessary to notch the overhead panel for the bracket.<br>If you are getting the after-market PlaneAround DOOR STRUT ATTACH BRACKETS, do not match drill with a #12 bit since the holes are already threaded for 10-32 bolts. Consider match drilling with a #22 bit, then enlarging the hole to size #12. You may have to chase the bracket threads with a 10-32 tap if the #22 drill bit damaged them. | ||
* Step 3: If you are getting the after-market PlaneAround DOOR STRUT ATTACH BRACKETS, two of the four bushings need to be narrower, 3/8 inch instead of 9/16. | * Step 3: If you are getting the after-market PlaneAround DOOR STRUT ATTACH BRACKETS, two of the four bushings need to be narrower, 3/8 inch instead of 9/16. | ||
== 45-17 == | |||
* Pin plates are not needed if using Planearound pins/guides. | |||
* If using McMaster seals you will do this completely different. You will remove the lip from the door opening on the cabin top until it is completely flat (parallel to the door). Consider using an angle grinder with stone wheel for this step. If the lip flares out (towards the door) at at any point it will need to be ground down. Consider a minimum gap of 3/8" all around when the door is closed and clamped flush. | |||
* Temporarily install the seal and shut/clamp the door. Make sure that the compressible part of the seal is compressed to no less than 1/4" all around. Make sure the door sits flush outside the plane. If the gap is not large enough, the seal will compress too much, and the door may bulge. | |||
* Once the gap is sufficiently wide, mix up some epoxy plus micro so it isn't runny and fill in the channel in the seal as you place it around the door. Close and clamp the door to its normal shut position. Let the epoxy dry. Then remove and throw away the seal, sand, paint, and otherwise finish the interior/exterior of the lip, then install fresh seal. | |||
== 45-19 == | == 45-19 == | ||