SECTION 45: CABIN DOORS & TRANSPARENCIES

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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.

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

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:

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

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.
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. 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.