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SECTION 45: CABIN DOORS & TRANSPARENCIES: Difference between revisions
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These steps are slightly different if using Aerosport low-profile exterior handles | These steps are slightly different if using Aerosport low-profile exterior handles | ||
== 45-15 == | |||
* Step 2: consider deferring the marking of the holes until you have installed the door seals and the strut. These items may slightly change where you want the door to sit. | |||
* Step 2: You can still use this same method to mark the door sill even if you are using the upgraded PlaneAround machined door pins. Follow all instructions normally including cutting and tapping the Van's door pins. Then screw in the double-ended screw that came with the PlaneAround 180-degree latch. Then fabricate two 2" pieces of aluminum using the scraps from cutting the original Van's door pins. Tap both ends. Screw one end into the double-ended screw, then screw the fabricated pointy screws into the other end. | |||
== 45-16 == | == 45-16 == | ||
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== 45-17 == | == 45-17 == | ||
* Pin plates are not needed if using | * 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. | * 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. | * 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. | * 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. | ||
* More information on installing the McMaster seals can be found here: [[Door Locks / Hinges / Handles]] | * More information on installing the McMaster seals can be found here: [[Door Locks / Hinges / Handles]] | ||
[[File:2025-07-05 11.20.12.jpg|none|thumb|Door jam flange sanded parallel to door ready for installation of epoxy-filled sacrificial McMaster Carr door seal.]] | |||
[[File:2025-07-05 11.20.01.jpg|none|thumb|Installed McMaster Carr door seals.]] | |||
== 45-19 == | == 45-19 == | ||