General comments before I move on: I did all of the installation with the doors still on the airplane to maintain and check alignment along the way. I made all of the required holes using a Dremel cutoff wheel for straight cuts and a spiral carbide bit for the odd shape holes. There are only a few places where simple drilling can be used due to shape or clearance issues.
Now moving on;
With the latch and cam gearbox firmly attached (drilling, countersinking, screwing) the rear pushrod is attached to the cam gearbox rack and threaded into the gearbox by taking the rear guide block out. Fairly easy with the door raised to where the bottom is horizontal. Once fished into position the cam rack is joined to the mid pushrod through the 3/8" hole that I mentioned to you in the last entry. The rear pushrod is marked in the fully open and fully closed positions and everything is disassembled. The pushrod is cut to length and cleaned up.
Assemble everything again and check for proper movement. I made the center marking point as described by Vans and threading it into the pins, marked the drill positions on the door jamb one at a time. I hand held the door in perfect alignment while marking each side, then drilled.
I added the Delrin guide blocks per Vans and Planearound (for the cam) instructions. A little reaming was needed for smooth action.
I added limit switches activated by each pin and wired them in series to a warning light for each door. Unless both pins are fully home, a red LED in the IP remains on (whenever the Master is on) for the left and right doors. I did not use the Vans magnetic switches as I prefer mechanical switches. I plan to add a home brew flasher circuit to make the warning lights flash.
door latch with limmit switch visable
rear switch with pin in place
door as seen through the front window hole with the LED sitting on top of the IP