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Rob's REBVAIR Project
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Date:  10-25-2016
Number of Hours:  40.00
Manual Reference:  
Brief Description:  gull-wing doors: part 2

These doors take a LOT of hours to build. All the gussets, all the tubing, sheet aluminum, spacers...the list seemingly goes on forever. There has to be at least 30 custom fabricated parts per door.

In these shots you can see the door in action. I used 0.093" material (4x3' sheet) from Home Depot for the window. Final install with rivets and silicone sealant will wait until after paint, as silicone will prevent paint adhesion.

Overall very pleased with these doors, and they have a surprisingly solid feel to them. Used EPDM rubber weather-strip (D-shaped extrusion 1/4" high) to seal everything up, with 3/8" strip used to fill the gap in the top corners.

28 lb gas lift struts complete the build and make getting in and out a breeze. Make sure there is enough clearance between the door and its frame to allow attachment of the lift-strut brackets. I was lucky....this time.

All in all, though tedious, this build was another success in that I didn't have to remake even one part. That's mostly due to helpful photos from Jesse, Si, Craig and others, and partly attributable to my fabrication skills developed over 9 years of building this plane. I really do enjoy moments like these.
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