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Steve & Nancy Riffe
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Date:  10-3-2016
Number of Hours:  3.00
Manual Reference:  8-70
Brief Description:  Baggage Door Redux-2

I drilled all holes in the inner skin up to 1/8”, then reamed them to #30. For the outer skin, I drilled all holes to #41. I cut a piece of hinge and clamped it to the skin/inboard angle, with a 1/32” clearance. I match drilled these holes to #41. Next, I used a -4 piece of hinge on the fuselage side of the hinge—on the previous door, edge distance for this side was very close. This gives a bit more width so no worries about edge distance. I then removed the inner skin and placed the door on the fuse. The door is a wee bit wider than the opening, so I removed it to trim the forward edge of the door skin. I used a wood working plane to shave the edge of the skin—works very slick. I set the door back on the fuse—it is difficult to always get it in the exact same location, so I decided to drill the hinge that will attach to the upper fuse skin. The manual says to have a helper crawl under the instrument panel and use a stick to hold the hinge in place—hmm, since I need to drill and no way will Nancy climb in there, I found another method. I cut a piece of wood almost the width of the F-873G-1 hinge support channel. I stuck this in the channel, then put the door in place with the hinge attached and wedged it between the wood and the support channel. I taped the door down, then match drilled thru the top skin into the hinge and wood support. Now, the door is fixed so that it fits in the same location each time. I removed and re-installed several more times while slowly trimming the fore and aft skin for a good fit. I need to roll the bottom edge of the door skin just a bit so that it will lay flat.
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Drilling hinge to door

Drilling hinge to door

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Used a plane to shave skin

Used a plane to shave skin

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Drilled hinge to top skin

Drilled hinge to top skin

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