Cutting the panel out of the baggage deck took some time. Once I marked the lines to be cut, I taped a metal straight edge on each line to use as a guide to steady a Dremel tool with a very thin cutting wheel. Surprisingly, I was able to get a clean and thin enough cut that the removed metal could be used in fabnricating the hinged door.
Installation of the latches required two small holes be cut in the door. The holes each measured about 1"x1.5" and were cut using the same technique as the large door. I was sure to cut them just a little small so they would fit nice and tight after some light filing.
Finally, I riveted a stiffener across the edge where the latches actually engage the deck. Aside from stiffening this area a bit, the angle aluminum took up the slack on the latch and ensures the access panel/door fits flush and snug to the deck. By the way, the angle aluminum used was some 1/2" x 1/2" x 1/16" material purchased at Ace Hardware. It was a perfect match for the requirement.
You will see below there are no stiffeners on the door at present. I may add a couple stiffeners later if the door has too much flex once the whole assembly is installed in the aircraft.
