Originally I was just going to install the round plexiglass vents that pop into the windshield, but several users said that in warmer climates they weren't that effective. I then remembered the flip-out vents that Van's sells for the RV-10 and RV-12, so I ordered a set.
The parts are first separated from each other, holes drilled up to #30, then cleco'd together. The whole assembly is then placed in the pre-punched hole (well, if you were building an RV) and everything is riveted.
I riveted one door together but left the other one un riveted just so that I could use the door for a pattern. Remember - my Sonex does not come pre-punched for this part!
There is a doubler frame that mounts to the insde of the fuselage so that the door looks flush from the outside. The trouble is that the hole in the frame is smaller by design than the door that opens, so I can't just lay the frame on the outside and cut the hole for the door.
I solved this by making a duplicate frame the exact same outer dimensions as the Van's frame; however, I will cut out the hole to match the flip-out door, which I can then use to mark the spot on the fuselage where the door should be cut.
