Tonight I added an angle stiffener behind the hinge and reduced the size of the side stiffeners to 3/4" x 3/4" angle with a more even bend profile. The entire turtle deck bulkhead flexed out when the door was cut out, so the stiffeners are needed for the door to sit flush against the doubler. Later I'll downsize the upper angle to match and then carefully trim the hole in the turtle deck to match the shape of the door, leaving about 0.040" gap so that the paint doesn't chip. After that, I can cut holes for the Hartwell latches and stiffen the tang in the top where the canopy track arcs over and bolts on.
