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Bob's RV-8 Build Site
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Date:  6-14-2019
Number of Hours:  6.60
Manual Reference:  
Brief Description:  Mid Cabin Covers #3

It is amazing how long it seems to take for some items. You think, I can knock this out in a couple hours and by the time it is done it takes over three times that amount!

Anyway, I got the entire door ready except countersinking and final deburring.

I started by making a doubler that would also act as a door stop. I felt that I wanted a thicker piece of metal for the cover as the Mid Cabin Cover is only .025 thick. I decided that .040 would be good as I also had a sheet in stock that I could use. In order to do so required additional work. To make up for the extra .015 of thickness, it means making a spacer for the outboard hinge half and making a spacer for the door stop doubler so when the door is shut it is flush with the Mid Cabin Cover.

Before selecting the .040 thickness I searched for .015 sheet aluminum which I found in my stack of trim stock. Ok .040 is a go. I had picked up some small MS20257-1 Piano hinge to make hinges for the console compartment and this Mid Cabin Cover. So I measured and cut the hinge.
After making the spacer I located and drilled the outboard hinge.

I then used poster board (which I have found soooo useful to make patterns) and made a pattern by tracing the door opening. I cut the door out of the .040 sheet leaving a smidge extra for fitting. I also made a pattern for the doubler/door stop and cut that out of a scrap piece of .025 sheet and then made a pattern and cut the spacer for the doubler.

Next I began to fit the door to the opening and the hinge. Next I cyphered the spacing for the rivet locations and marked and drilled all the holes.

And that's how you spend 6.6 hours of life on building your dream machine. It really goes fast when you get into it.....sometimes in the late afternoon I realize I haven't eaten anything since breakfast!!
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Cover with Door stop

Cover with Door stop

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Fitting door and hinge

Fitting door and hinge

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Almost ready to paint

Almost ready to paint

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