Doors

The photos below are arranged chronologically and illustrate the process of installing the doors.

Click on thumbnails to view larger versions of the pics!

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Pre-molded doors with window and latch mechanism installed. Doors with Hangar 18 signature flush window installation. Brad Flecker demonstrates use of door placement tool: This guide was created by making a fiberglass imprint of the edges of the pre-fab doors. As it conforms to the contours of the doors, it can serve as a precise guide for placement of the door cuts. This allows quick, easy outlining of the door on the fuselage and results in a close to perfect fit of the door into the fuselage after confirmation of placement by measurements as the previously drawn lines may be slightly off. View of the top edge of the door cut out.
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Overview of door cut out. The piece removed can be seen inside fuselage. Preparation for creation of door flange. The just cut out piece of fuselage is reinserted in fuselage cut out and secured in place by tape. The INNER surface of the cutout is covered by duct tape as seen in the next photo. Inner surface of fuselage cutout seen inserted in pilot door opening. Duct tape is used to cover the inner surface over which a fiberglass layup is placed. After curing, the rim of fuselage cutout is peeled out leaving a flange around the perfectly fitted door opening.
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Doors installed. This technique yielded a virtually perfect fit on first try with only a very minimal need for readjustment! Pilot door seen closed with a nice fit! View of pilot side door flange with latch pin sockets installed. Another view of latch pin sockets.

Comments, questions, and suggestions are welcome! email: rich@rguerra.com

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