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Dave's RV-10 Build Log
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Date:  7-5-2017
Number of Hours:  7.00
Manual Reference:  
Brief Description:  Door Latches

Began fabrication of the door latches.

Since I am installing the after market Plane Around 180 deg. door latch with 3rd cam lock for more secure latching, I am working from 2 different sets of instructions. I have also ordered the Plane Around door pins and the Aerosport outside door handles, but haven't received them yet, so trying to work around these items to avoid re-doing work.

Fabricated the main door operating gear mechanisms per Van's plans.
Installed the nut plates inside of the inner door handles per Van's plans. Used forcepts to hold the nutplate inside the handle while installing clecoes and a screw prior to riveting them in. Counter sunk the rivet holes, even though the plans didn't call for this.

Cut the opening and slot in the middle of the left door bottom for the 3rd latch gear box, per the Plane Around instructions. Used a combination of dremel tool with diamond cutting disk, diamond bur, and thin/flat Perma Grit to create the rectangular hole in the bottom of the door. Drilled the 1/2 in hole per the instructions using a step drill, and then used a larger diamond disk with the dremel to cut the slot from the bottom to the hole. Used the 1/2 in. inner door handle shaft to position the 3rd latch gear cover in place and 2 cleco clamps to hold it while drilling the mounting holes.

Mixed up a small batch of epoxy with cab-o-sil to a thickened liquid, then used a syringe to inject the mix into small areas of the flanges where the inner and outer skins of the door did not fully bond during their glue up. Used many small binder clips (from Home Depot) as clamps to hold the areas while the epoxy cures. Will repeat this several times while turning the doors in order to fully bond all flange sides.
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