I faired in the door surround with 80 grit > 180 > 400 and used some additional 5 minute filler (ISOPON P38 Easy Sand).
Gave the door a nervous punch and thanks to the shiney packing tape it came out clean and then I sanded down the flange. VERY pleased with the result so far.
Riveted the hinge to the cowl.
Whilst steel keeping the door the same size (I will sand for paint after the hinge support is riveted). I taped it in position and bonded the hidden hinge door support.
Notes.
* I did not use the spring (too strong) * The support did not lay flat so used one of the holes I had pre-drilled, then drilled into the door and cleco'd whilst the peanut butter epoxy shim cured.
