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Bruces Web Site
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Date: 1-28-2013
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Number of Hours: 2.50
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Manual Reference:
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Brief Description: Right door, fit start hinges
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Marked and cut back gutter on right side. Trimmed door top and bottom, beveled edges and started fitting to fues. In about 2 tries, it was close enough to put on straps to hold it in position. Did more marking and trimming and got it to fit well enough to put on the hinges. Started on hinges.
How to do the door second trim in about 2 hour vrs about 5 for the first:
1.Complete the rough trim that leaves the outside of the door even with the top of the 45 degree bevel on the cabin top. Trim it just a shade inside this line on the sides. Mark two lines on the door/cabin top to locate the door and cut off the cleco tabs.
.2. Recognize that the door is going to drop the thickness of the two skins and move into the cabin the same amount. It is between 1/8 and 3/16". Trim that amount off the bottom and top of the door. Reshape the curves on the top of the door.
3. Sand the 45 degree bevel all around the door. Actually, you want the bevel to be slightly flatter than that.
4. Fit the door using the lines, the door mark should be slightly lower now and the fit may be close.
5. Sand the problem areas until it is close, make the bottom fit. When there, attach the door with two strips of alum, see photo, and one on the top.
6. Sand the parts that are causing a problem using two sheets of #60 or 80 sandpaper with the sanding side out sliding it between the door and cabin top. Get it level with the cabin top and install the hinges.
Then, install the door latches and hardware. Now the door is in its "final" position. Sand the gap between the top and door til it is about 1 or 2 business cards wide and even all around.
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