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Ron's Web Site
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Date: 11-26-2006
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Number of Hours: 42.50
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Manual Reference:
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Brief Description: Cargo Doors
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I made the cargo doors out of .032 2024-T3; originally I tried 6-32 countersunk machine screws, but I wasn't happy with the center-edge distance that was necessary on the aft cargo door owing to the overlap of the front cargo door. So, I scrapped a door and went to 4-40 countersunk machine screws, which seems to fit the .035 aluminum better, with the exception of the screws around the window, which remained 6-32. I learned a few things. First of all, the panels extend to the center of the hinge lines. Second, just because the frames look straight, doesn't mean that they are, which becomes important when you are laying out the screw holes. Also, a shrinker comes in handy to seal the aft portion of the front door near the latch system. Another detail is that if you want the aft door to open fully, you need to trim the aft edge to match the fuselage contour when the aft door is fully open - see image 1. I put a small removeable cable on the aft door to stop the door from opening so fully that it cuts the fabric.The outer panel should overlay the plexi window somewhat; I used 5/8 inch additional metal aft of the front tube, and fabricated a piece of .025 joggled aluminum to clamp the plexi to the panel, which is placed between the panel and the front tube of the door and which is picked up by the front panel screws. I originally thought about using fabric laid around the door frame with some small aluminum panels to seal the door, but gave up on it owing to the complexity. I still used the small piece of steel welded on the latch handle to seal the latch slot previously described, but had to make an access panel, so the panel could be removed and replaced. Since I'm going without an interior, I went ahead and primed the doors with the same two-layered epoxy system Avipro uses on the fuselage. I can only hope the front doors won't be so much fun!
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The aft door rear edge after trimming.
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Outer view.
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Inner view.
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