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Door alignment / fit
I have both doors trimmed and mounted now with the handles installed. I'm about to drill the holes into the fuselage for the pins but want to make sure I'm doing it right. I'm somewhat disappointed in the door fit though. My doors sit a bit lower the the cabin top on the curves but are even on the top and just proud at the bottom. I'm working with some washer combinations on the mounts but that won't fix everything.
Do folks just glob on the filler and start sanding? I had no issues bonding the doors together, it's almost like the molds for my cabin top and doors aren't the same! The biggest difference is 3/16" in some spots. I just ordered the Cee Bailey's windows, should I wait until I have those to just put in place from time to time to help get a smooth profile as I fill in the low spots on the doors? I'll post a few pictures tonight. |
I would wait for final tweaking until the windows are in place. I found multiple places that need TLC. Many of the cabin covers have a flat spot between the rear window and the door that has to be built up.
Also, only use micro for very small areas. I used narrow fiberglass strips wherever possible for increased strength. Some places I needed to build up 1/8? to 1/4?. |
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Did you clamp/strap/etc. the doors to the cabin top when you drilled the halves together? |
I did mine a couple of months ago. One door was pretty good, the other not as much, though probably only an 1/8" off in worst spot. Mine were clamped tight and cleco in spots. I think it has something to do with how the inner half is aligned with the top and the effect after mounting and finding a compromise, but not sure.
Only one thing to do at this point: Just slobber on the filler to make them level/flush. :) I would use epoxy with cabosil to get close. Once close, layer on the filler of choice. I work mostly with polyester fillers. 3/16" is too thick for pure poly filler, though it is done often. Others like Micro. As others mentioned, there isn't really anything to do about the divot in the top between the rear window and door (B pillar for automotive types). Larry |
Check
Are you absolutely sure that you have the hinges in the correct locations? The forward and aft hinges are NOT the same...
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I'd like to echo what Bob just brought up. I was able to significantly adjust the fit of my doors by moving the hinges. I have one door that closes perfect and the other one is just a little off and I'm hoping to finalize it after I get my windows in.
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Mine are about the same as the OP doors, but I put it down to the old green moldings... :)
I think some of my problem may be how I clamped the doors after bonding - if the clamps are a bit too far outwards from the door a little bit of a curve may be introduced. Some shims under the hinges on the door side helped, and I think the worse error is just over 1/8 inch at the middle of the curve, front and rear. Like some of the earlier posters, one side is quite a bit better than the other even though I thought they were bonded the same. Besides the filling needed, this error is starting to affect my next step which is the creation of an even 1/4 inch gap for the McMaster seals. Where the door is low in the middle of the curve more of the cabin gutter rail needs to be removed, seemingly to a knife edge in a few spots. Just more glass dust I guess...:) As a note to Bob's flat spot comment, all of the filling I need seems to be on the doors, not the cabin cover. |
Thanks for the help. I forgot to get pictures last night as I wasn't feeling well.
Yes, the hinges are in the correct location. Mine is similar as one door isn't as bad as the other. I used the cleco method with a few clamps as Justin Twilbeck and others did by clecoing the doors to the cabin top in drilled holes. I think I'll have to lay up a few layers of glass then use filler. The worst door was made better with playing washer musical chairs last night. |
Just got my finishing kit last night..
..and I'm not too excited about starting on my doors. Thanks for the insights. This will help me not get too agitated if/when I have spots that don't match up exactly.
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hinges
Make sure you figure the hinges out early on as the fronts and backs are different...
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