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Patrick Kelley (Flion)
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Date:  7-24-2013
Number of Hours:  5.00
Manual Reference:  None
Brief Description:  Final fit pilot door; hinge work

After spending a couple of hours final sanding the door to fit, I drilled it to the hinges. In the first picture, you can see I've drilled the outboard locations and installed bolts (not screws, since it hasn't been countersunk. I've already removed the duct tape and am ready to lift the door, bracing it with a piece of wood like the other door, and drill the inboard locations. Then I removed a bolt and countersunk for the screw, replaciing with screws as I went. Finally, I removed both doors and the hinges. Since I am using the McMaster-Carr seal, I will need to cap the door bolt well, which means I won't be able to use nuts there. Instead, I am installing nutplates on the door hinges. In the third picture, you can see that I am drilling, using the nutplates as a guide, in a drill press. Once the holes are done, I am countersinking the back side for flush rivets so the finished plate will fit flush to the door. I was partway through this procedure when it began to thunderstorm, which made it not the smartest idea to be around electrical equipment in a hangar, so I will finish this tomorrow. Then the hinges will be powder-coated, the holes reamed out, and the nutplates riveted on. The cabin top plates will be coated with mold release and attached, then the area around them will be filled with flox and epoxy to help finish the cabin top.
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