Drilled pilot holes for locks/latches in baggage door. Temporarily installed right cargo tie down rail. Installed two cargo rings abeam pilot holes in door. Put nylon ropes through pilot holes, through right side cargo rings and out cabin door. Pulling on theses ropes applies closing pressure on cargo door at the same place that the latches will. Masked inside of baggage door with release tape. Masked inside joggle in door frame with black electrical tape (this area gets foam seal applied). Experimented with tiny pieces of phenolic of varying thickness, mostly 1/16", in the outer joggle of the door frame. Without these blocks, the door closes too deep in the frame at some points. When acceptable combination of blocks was found to produce a good fit, the blocks were instant glued in place. Sue painted epoxy on door frame, I applied micro on top of epoxy covering all blocks and the entire outer joggle of the frame. Door was closed on the wet micro and the ropes were pulled and tied off to produce a tight closure. After partial cure of micro, ran a razor knife along kerf with the knife pressed against the door. This should produce a very thin, uniform gap between the door and the frame. We'll see in the morning.
