Door Locks / Hinges / Handles: Difference between revisions

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Revision as of 16:22, 11 July 2025

Locks & Keys

See Door Locks for more information.

Seals

Cabin Door Seals

Many builders decide to put the door seals on the fuselage side instead of onto the inside of the door.
Two McMaster order numbers are being used: 1120A311 (lip on inside, 3/16 edge thickness, 3/8 high):

1120A311
and 1120A313 (lip on outside, 3/16 edge thickness, 3/8 high). Since you are building up the inside edge, the lip is better to be on the inside as the groove for it will automatically form when using a throwaway seal as mold.
Some builders prefer the 1120A411 variant which is for 1/4 edge thick edges.
Builders usually sacrifice one set of seals as mold to form out the edges, then replace it with a clean second set. This procedure will need 100 ft total.
Some builders experience a gap where the ends meet after some time, see this FB thread.
See also:
- FB thread
- Mark's builder log
- VAF thread
- VAF thread
- Glen's builder log
- Justin Twilbeck's log
- BuildFlyGo's video
- Ivan Kristensen's video with door trim measurements
- Ivan Kristensen's door seal photos (now on smugmug, no longer on ivankristensen.phanfare.com). The sparse text for photos is available on the web archive.
- Les Kearney's door seal compilation pdf (originally posted to the Matronics mailing list)
- FB thread
Some builders use the standard Vans way of putting the seals on the doors but use better seals sold by McMaster.
- See VAF thread

Luggage Door Seals

Aircraft Door Seals
See also this VAF Thread

Door Strut Upgrades

Upgraded strut brackets (especially useful if you use McMaster door seals)
Heavy Duty Door Strut from Vans (600 instead of 500N)
Bansbach easylift door strut A1A1F50-100-287 part#10017Y1 (600N instead of 500N, call to order)
Ordering 650N at Bansbach: Select the 650N version of B0N0F50-100-247/XXXN, add 2 of those, then add 4 of the end fittings A1 M8 Aluminum Hinge Eye Endfitting. These end fittings yield a total length of the 287mm similar to the other fully assembled struts. First timers can try coupon code 15PERCENTOFF.
Tim Olson's build page on struts
Door strut hardware (FB 3/22/2022)
See also this FB thread.

Hinges

Machined hinge capture plates make removing and re-installing the doors much easier
Airward hinge reinforcement kit, see this [FB thread 1/2024

Other Enhanced Door Parts / Kits / Upgrades

Aerosport Products
Planearound, see also this FB thread

180 Degree Door Latch and Low Profile Handle Hints

The Aerosport door handle kit assumes a bonded wall thickness of approximately 0.160 inches. It does not include a mechanism to accommodate deviations from this thickness.

If the door mechanism holes are drilled prior to bonding, and clecos are used during curing, the door halves may compress tightly in the lock area. This can result in a final wall thickness of only about 0.112 inches—leaving a 0.050-inch discrepancy. This difference will cause the outer lock cover to sit proud and not flush with the surface. Conversely, if your wall thickness exceeds 0.160 inches, the lock cylinder will sit recessed within the outer cover. For doors with thinner walls, a workaround is to fabricate a spacer to mount beneath the strike plate. This spacer should have holes that match the diameter of those in the door skin. For doors with thicker walls, consider designing a 3D-printed collar around the lock.

PlaneAround 180 degree latch together with Aerosport interior door handle beauty cover causing binding (FB 10/11/2022)
PlaneAround FB thread
Low profile handle + 180 degree FB thread 6/2023, FB thread 9/2023 FB thread 11/2023
Documentation set at Planearound, includes link to document written by David Peterson which is a revised Vans chapter 45 document with the various modifications compiled in
Damazio's write-up of the 180 degree door latch install
Videos
- Ed's low profile door handle install
- Austin's door latch and handle install

@@ Line 45: / Line 45: @@
 == 180 Degree Door Latch and Low Profile Handle Hints ==
-* The Aerosport low profile door handle kit makes an assumption on the thickness of the two door halves bonded together of some 160/1000th. There is no mechanism of coping with other thicknesses. If you drill the door mechanism holes before the bonding, and use clecos during curing, the halves will sit together very tightly in the door lock area, and the wall will only be about 112/1000th thick. So you are missing some 50/1000th of door thickness. This will manifest itself in the outer lock cover not wanting to sit down flush. If your wall thickness is more than 160/1000th, the door lock will sit recessed in the cover. Workaround for too thin walls is to make a spacer that sits underneath the strike plate with holes having the diameter of the holes in the outer door.<br>[[File:2025-07-09 12-48-09.jpg|100px]]
+* The Aerosport door handle kit assumes a bonded wall thickness of approximately 0.160 inches. It does not include a mechanism to accommodate deviations from this thickness.
+If the door mechanism holes are drilled prior to bonding, and clecos are used during curing, the door halves may compress tightly in the lock area. This can result in a final wall thickness of only about 0.112 inches—leaving a 0.050-inch discrepancy. This difference will cause the outer lock cover to sit proud and not flush with the surface.
+Conversely, if your wall thickness exceeds 0.160 inches, the lock cylinder will sit recessed within the outer cover.
+For doors with thinner walls, a workaround is to fabricate a spacer to mount beneath the strike plate. This spacer should have holes that match the diameter of those in the door skin. For doors with thicker walls, consider designing a 3D-printed collar around the lock.<br>[[File:2025-07-09 12-48-09.jpg|100px]]
 * PlaneAround 180 degree latch together with Aerosport interior door handle beauty cover causing binding [https://www.facebook.com/groups/vansrv10/posts/5427322947388760 (FB 10/11/2022)]
 * PlaneAround [https://www.facebook.com/groups/vansrv10/posts/6065285950259120/ FB thread]