So far building the baggage door has been pretty embarrassing in terms of the number of scrapped and rebuilt parts. After coming up with the contours for the formers by creating templates from my actual forward skin (There is normally too much distortion to trust the profile shown on the plans), I created some MDF forms for the inner door bulkheads. On the first bulkheads, I put tooling holes in and area that will need to be left untouched for the future installation of the hold-down blocks (scrapped parts #1). Next, I got clever and put a shrink and stretch into the flanges before I bent them with the form. However, it turned out that this moved where the part edges with in the form such that the flanges ended up short (scrapped parts #2). Next I drilled a hole poorly in the new blank (scrapped part #3) I should also point out that I attempted to use the panel cut from the skin as the door. This means that the cut had to be very accurate and thin to end up with good gaps when installed. However, after cutting out the door, I was not happy with the straightness and any filing would make the gap too big, (scrapped part #4) At this point, I stopped for the day. (Sometimes that is just the best thing to do...ha ha..)
