This is my first attempt to create gasket around the cooler box door. First I read up a little on this and it looked like wax paper was the best solution to protect the fire wall from the RTV sticking. Several people had tried the wax approach with bad results. So I cut out some wax paper that just fit inside the box area where the door would touch. I cut it big enough to allow it to slide under the flanges of the box frame, then taped it down to the fire wall (just taped the outboard side). This worked out really well, especially as I found out later that made clean-up easy. Next, I applied RTV on the door (while it was installed) then closed the door and applied tape to hold in down in place against the firewall. Well I obviously applied too big a bead of RTV around the door, because it spread out across the first set of holes in the firewall. I’m so glad I went the wax paper route; otherwise this would have been a real mess. Covering the holes would probably have not been too big a deal, since it doesn’t matter when the door is closed, but it just looked bad. So after a couple hours or so I decided to start over. The cleanup was easy, the door just wiped clean and the wax paper just lifted off. I’ll try again tomorrow.
