This morning I added L angle backing to the wing locker door. The purpose of the L angles is to stiffen the door so that it remains tight against the wing with the same airfoil shape. The plans call for 3 L angles in an "H" pattern (1 spanwise, 2 chordwise), but I added a second spanwise L and changed the pattern from an "H" to a rectangle.
First step was to lay out and drill the rivet lines on the door according to the (slightly modified) plans. Then I measured, cut, and clamped the L angles to the door and used the already drilled rivet lines to align the L angles and drill them out. Everything was assembled with clecos and the door was checked for fit within the opening in the wing skin.
Once I was assured of a good fit, I used the Zenith-provided crimp tool to make 4 crimps in each of the 2 chordwise L angles in order to force the door into curve shape to match the airfoil shape of the wing. Next up: Dzus fasteners for the door.
The wing locker door held open to show the 4 L angles. Note the crimps and how the door curves.
The wing locker door closed. A couple of minor adjustments remain to match the wing curve perfectly.
