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Patrick Kelley (Flion)
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Date:  7-6-2013
Number of Hours:  4.00
Manual Reference:  45
Brief Description:  Trim and fit pilot door halves together

After reading up on the process, I trimmed out the door opening in the cabin top some more and, while I was at it, final drilled the #12 and #19 holes in the opening and countersunk them for screws. Then I marked the trim lines on the door halves, including the cleco lines on the outer door half (and just made reference marks for the 3/4" line; I'm still thinking there must be a better way to do this using the joggle rather than just freehand). After marking the door halves, I cut to the trim lines and sanded everything smooth, including the insides of both halves where they will bond. I installed the screws in the door opening and marked for the open rivet locations. Then I clecoed the door halves to the airframe using the outer index holes (the window indices were useless. Starting at the bottom, I drilled the door to the index locations and worked upward. Then, clamping, drilling and clecoing as I went, I worked up the sides of the door and secured the window opening. Notice that I clamped the door to the cabin top to match the contour. When done, the gap at the top was about 1/8", which is easily weighed down for bonding.
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