I decided to add a small step to the left skid to make it easier to get in and out without putting weight on the fragile cabin door opening.
After spending about half an hour getting in and out of the cabin using blocks of wood to determine where the step should be, I mocked up the step in cardboard then went to work creating it in aluminum. The side pieces were cut from 1/8" on the band saw then smoothed on the belt sander. The top plate is 1/4" aluminum, cut on the band saw then milled square and true.
Tapped three 10-32 holes into each edge of the top plate to attach it to the sides with button head stainless screws.
Cut lightening holes in the sides and top then sanded and jeweled.
Installed on the helicopter using two slightly longer bolts through the front skid mount, then tested it out by getting in and out about 5 times and it seems plenty sturdy.
Preparing to cut lightening holes in the side frames
