I shaped the final door rod guide block to fit the cabin fiberglass and installed it on the left aft side of the fuselage. Door mechanism works smoothly. Next task is to install the Master Carr 3/16 bulb seal. To start, the cabin door opening has to be shaped to receive the seal. That means removing some of the glass...and adding some back in to keep the seal square. After latching the right door, I drew a cut line around the inside so that I would have a 1/4 gap where the seal will sit. I rough cut just short of the line and then sanded to the line and got the entire door opening cut. I then mixed a little epoxy and brushed (wet) the horizontal section (above the door). Once wet, I added cabosil and placed it along the edge to start the build up process. I plan to shape it to receive the seal once it cures. The lower horizontal door needs to be filled in about 1/8 if an inch. I plan to put 1/4" foam on the bottom of the door and fill the gap. Once set, I will remove the 1/4" foam. That should leave me a nice 1/4" gap for my seal. After the seal is installed, I will add a 1/4" bead of silicon to reestablish the rain gutter.
