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Steves S-20 Build Site.
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Date:  6-15-2016
Number of Hours:  20.00
Manual Reference:  
Brief Description:  Covered The Doors.

The last several sessions were dedicated towards covering the doors.

The manual suggests that the inside of the doors should be covered first so the smooth side is on the outside, but all the outside seams are covered up by the window trim, so I covered the inside first and put the seam on the outside.

I did not glue the fabric to the inside of the top rail. The geometry of the door frame draws the fabric away from this top tube on the inside, and I thought it would look better to let the fabric flow than to glue it to the tube. This meant that the fabric was glued to two faces of the tube instead of the three recommended in the manual, but I was comfortable with this since the glue joint did not slip during ironing, and the fabric on the inside of the door is not critical to flight.

I used 2" bias tape along the bottom of the door. In retrospect, I could have saved myself some grief if I had also used bias tape on the top. As it was I needed to work with the iron both before and after the gluing process to get everything smoothed out.

The manual specifies a patch on the inside only of the lower front corner where the door latch handle is located. I thought that one on the outside would also be beneficial, and this was confirmed in photos of the factory plane. I also put a patch on both the inside and outside of the lower rear corners in the area of the secondary door latch.

In the door handle location I made the first cuts in the fabric to be located below the handle, and I cut 1/2" circles to clear the handle. For the patch I used 1/4" circles, and I made a cut forward and rearward from the handle. On the tapes I again used the 1/4 circles and made the cuts below the handle. This worked out well.
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Patches on both inside and outside.

Patches on both inside and outside.

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Door handle detail.

Door handle detail.

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Finished door temporarily installed.

Finished door temporarily installed.

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