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Patrick Kelley (Flion)
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Date: 7-26-2013
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Number of Hours: 6.00
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Manual Reference: 45
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Brief Description: Assemble inner door handles
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During this build session, I finished drilling and countersinking the door hinges for nutplates. As I finished one, I dumped it and the nutplates, well soaked in cutting oil, into solvent and then cleaned and marked them before drilling the next one. All the hinge plates went to the powder coater at the end of the day.
In between, I assembled the inner door levers. I've been shy about putting manual references because the doors are being modded for the McMaster-Carr seal and flush outer handle. With the outer handle, I am doing the hidden latch release. So, after cutting the handle tubes, I sent the inner tube to a machinist friend who tapped it outboard for the release button. Today, I assembled the nutplates to the handles and the inner tube to the handle assembly with the spring and roll pin. Then I tapped the gear and assembled it to the handle, grinding the handle tube flush with the face of the gear. After removing the gear and adding the latch plate, I reassembled the gear with locktite in the screws. Finally, I cut a piece of all-thread to take the place of the button, cut a notch for a screwdriver in the end, and screwed it into the inner tube until it was just under flush with the gear, setting it with locktite. Now the handles are ready to go in the doors.
Rivet count: 4 Total: 15861 - Plus 549 done at Van's
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