I decided that the problem with the directions is they have you rivet on the door ribs on the bench, I thought fitting it to the plane then riveting to hold the door would be better. So that is what I did, I put the door with the ribs held with clecoes in place then duct taped it down. Then used some cheap pop rivets to rivet the holes at the sharp part of the curve, about 16 rivets total. I then removed the door and riveted the remaining rivets with AN426 rivets checking to see that it maintains the fit as I went along. After all the other rivets were done I drilled out the pop rivets and set a flush rivet one at a time. The door held it shape and is about as good as I can get. I have a small gap at the forward edge but this door seems much better than the last one. My fit problem has more to do with the floppy part of the firewall and how that flange was riveted, I am not going to make this better at this point I will take what I have. I am doing the proseal trick instead of trying to rivet the inner skin by lying on my back on the floor. This worked well with the last door. Right now the inner skin is clecoed and duct taped in place while the proseal cures, after a couple days I will remove it and complete the riveting.
Aft seam, with light touch. Curve matches much better.
