After trimming the rest of the door pieces, I sanded their mating joints. Two of the six alignment holes did not align properly...in fact, they were not even close. Even though 4 of the 6 were perfect and the doors fit the cabin shell very well, I called Vans tech support to get their opinion. They were aware of the problem and assured me that it would not be a problem. They said many builders had the same issue with the exact holes and to just ignore those two holes. I did cleco the door shells to the fuselage to get a feel for how they fit. So far, so good. I also called Sean at Plane Around today to find out more about his third latch modification. He will send me a file on how it works. Looks like a quality product that would increase the level of safety for the door.
