One of the things I've been debating is whether or not to fab some door hinge covers like Robin Marks and Sheril Hilton did. Up til today it's been an 'experiment' in that I fabbed some fiberglass covers and sanded then to size and shape. I debated whether to mount them flush with the cabin cover or whether to route some of the cover out and recess them slightly. in the end I decided that it would be better to recess them. A quick trip to Home Depot to pick up a couple of attachments and fittings and then I dug in on one, figuring that if I screwed it up I could always fill it and sand it. I traced the outline with a finepoint Sharpie using the fiberglass cover, and then CAREFULLY routed out about 3/64" -1/16" of material, I used some needle files to 'true-up' the edges the result was pretty good and convinced me to proceed. with the covers having a 'dome' I needed to use some stand-offs to get the proper space between the bottom of the cover and the top of the hinge, Some nylon spacers from Ace hdwr and some thin washers epoxied to the underside of the cover yeilded the right stand-off. I match drilled the cover and the hinge using #36 drill bit, then tapped the hinge cover w/ a 6-32 tap. countersunk the cover for the #6 stainless steel screws and Viola! I still need to cut out a slot between the cabin cover and the door to allow for a portion of the hinge to move upward as the door opens, I'll wait until I get the forward cover mounted to do that. I've already fabbed 3 covers, and before quitting tonight I layed up the 4th.
Dremel routing an area to accept the hinge covers
Fiberglass hinge cover sitting in its position covering the right aft hinge
Combination of nylon spacers and thing steel washers provide proper stand-off
