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Steve's CH750 Cruzer (N750SB)
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Date:  9-30-2018
Number of Hours:  10.75
Manual Reference:  
Brief Description:  Installed new passenger side bubble

Started installing the new door bubbles I picked up at Zenith last weekend at Open Hangar Days. Started by removing the old cracked bubble. Used it to confirm I could safely cut flanges with my band saw. Laid the new bubble in place on the frame and positioned it as best I could for having the flats on the frame. As expected, the flat for the handle hole was aft of my existing bracket. With the bubble clamped to the frame, I drilled new holes across the top to match the existing holes. Carefully used an acrylic bit. Laid tape to indicate top trim line. Took to the band saw and trimmed the top. With the top trimmed, I repositioned on the frame and clecoed along the top now that it was trimmed and sat below the piano hinge barrels. With the bubble sitting flat, I re-drilled the remaining holes and cleco'd. Re-hung the door and taped trim lines on the overhanging bubble. This was one thing I messed up on the 1st time. The bubble is supposed to hang beyond the frame to help close the gap between the door frame and fuselage. Back to the band saw and trimmed the remaining sides. Re-assembled, cleco'd and test hung again. Some additional filing and sanding to get a good fit. Un-hung the door and marked the correct position for the handle bracket. Removed bubble, drilled out the bracket rivets, positioned and drilled for the new bracket location matching the shaped flat on the bubble. Re-riveted the bracket in the new location. Reattached the bubble and drilled and filed the hole for the handle shaft. Assembled the handle hardware and used loctite on the threads. Added loctite to front latch as well. Riveted the bubble with aluminum rivets. Re-hung and examined stker plate in relation to the new handle location. As expected, it needed to move aft. Drilled out the striker plate and re-drilled and riveted. Tested and works well. A little bit more sanding of the edges to eliminate interference and I called it done.

DO NOT POSITION STRIKER PLATES UNTIL YOU HAVE THE BUBBLE DOORS HUNG AND KNOW THE EXACT LOCATION OF YOUR DOO
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New bubble installed

New bubble installed

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