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Deems RV10 Project
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Date: 5-2-2008
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Number of Hours: 4.50
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Manual Reference: Sec Home-61
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Brief Description: Sec Home-61
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Today's task was to fix/repair the hinge cover for the pilot door, fabricate the hinge covers for the copilot door and reinstall the doors and then grind/sand the pilot door for fit of the door seal material. For the pilot rear hinge cover, I ground out most of the old cover, but left the straight/flat piece that works with the door seal, I also ground out more material in-line with the gas strut to allow for clearance on the backside of rthe hinge area. With the hinges attached to the door, I wettedout a 2 ply lay-up , trimmed it to aprox size, and then carefully pressed it in place, trying to get the max clearance for the support bracket. when it cured, I sanded it to blend with the remainder of the door, and it looks pretty good. The Co-pilot door also required some work to allow for more bracket clearance, and some relief for the gas strut itself (same as other side), After grinding/sanding the relief contours, I cut some small pieces of glass and layed them up, cured them w/ halogen lights. and then used Metal Galze to fair/blend everything together. Remounted both doors, and then used the HF angle grinder and sanding disc to grind/sand back the cabin cover so that there's enough gap/clearance to install the door seal material. used some test strips of door seal, and basically repeated the process I used for the co-pilot. I've got a TON of dust in the garage. Tomorrow, I'll check everything again, make any final sanding corrections, and then CLEAN-UP.
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Co-pilot door hinge covers filled/sanded
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pilot door aft hinge cover fixed/repaired to allow for clearance w/ strut bracket
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Cabin cover ground/sanded uniformly for door seal.
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