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Date:  3-19-2017
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Fitting the door

This may not be final since the hinges might allow some movement.

With a belt sander I marked and sanded, marked and sanded until I had an even gap of about 3/32" all around. It is not perfect because there are some irregularities in the cabin top that will need a little attention.

I did not have to move the alignment holes at all. With sanding, the door slowly transitioned into the hole and a flush fit. Beveling back the underside of the door to fit the curvature of the canopy gave about 1/16" clearance.

With the door fitting slowly into place, I was finally able to sand to fit the canopy opening edge. A 4 1/2" angle grinder with a medium flap disk makes quick work of the final shaping.
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top fit

top fit

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forward fit

forward fit

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