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BushCaddy ELSA
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Date:  4-4-2007
Number of Hours:  2.50
Manual Reference:  None
Brief Description:  Completed cargo door installation

There are no instructions for the cargo door but they are fairly straight forward. After the left cabin skin is drilled and held in place with clecos the outside frame can be inserted in fuselage section and traced on the back side of the skin. The frame should be placed as far right as possible to alleviate it interfering with the aileron cable. After removing the side skin draw a line in the middle of the lines traced on the back, this gives you a reveal of half the frame for the door to seal on. I used a cut off tool in my air grinder to make a cut on each of the four sides then used a jig saw to cut it out and filed the edges clean and used a rat tail file to round the corners. I used the cut out peace of skin to cover the door frame. I have ordered some U rubber from Aircraft Spruce that will go on the over hanging edge of the door skin to seal on the outside frame. I used 410 rivets to rivet the skin on cargo door and cabin skin on fuselage side. I held off from riveting the corner edge of the fuselage to cabin skin as I am making a drip edge for over the cargo door and the cabin side of the skin is riveted with solid rivets. The hinges had to be tweaked to set flat as the front hinge sets on the cabin side and with it at a slight angle to the fuselage I had to bring the hinge bolt closer to the skin. I set the hinges in place and riveted the cabin side with 470-4-8 rivets and the door side with 414 rivets at the door frame and one 410 rivet from hinge plate to skin. I had to straighten the door latch that came with the lock. I cut out for the lock with the cut off in the air grinder and installed it in the door. I riveted the cabin skin along the back and bottom of the cabin with 470-4-6 rivets. Installed drip edge over cargo door with 410 rivets.
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Cargo door in place

Cargo door in place

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Cargo door latch from the inside

Cargo door latch from the inside

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Cargo door

Cargo door

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