Transferred the template for the doubler on .40 aluminum sheet. I used the band saw to cut out the outside of the doubler. I then used a hand held jug saw to cut the inside line. Deburred, and used a hole layout fan to mark for the holes to be drilled. I used a drill press to drill all marked holes. I then fastened the doubler to the fuselage and match drilled all holes including the lower hinge. While the doubler was clecoed to the fuselage, I placed the door template for fit on to the doubler. Template fit pretty well. I then transferred the door template to .25 aluminum sheet and cut out on the ban saw. Deburred and fit door skin between hinge and doubler. Match drilled the door skin to hinge. Removed all and final deburred, dimpled, the alodine process etc.
