Inner and Outer Door Shell Alignment
 

Looking for some advice from those that have been there before me. The inner and outer door shells each have six molded-in dimples that are drilled-out and used as index alignment points for the inner and outer door shells. I have drilled them out and the four lower index points for the inner and outer shells align perfectly. However the top two index points of the two shells are off by 5/16". Not sure why this is. The doors nest together very nicely with four clecos in the lower four index holes. Do I just drill new holes and keep building, or is this mis-alignment going to cause a problem later with door fitting? Anyone else experience this issue? Any advice will be appreciated.
Thanks,
Rick

Use the ones that line up and drill new holes for the ones that don't. I had same issue and found out it's common.

Exactly this.
Just finished bonding my doors and only had 2 or 3 holes line up reasonably.

Thanks guys.
This gives me some confidence to keeping building on.
I'll drill a few new holes.

Just a minor advice I wish I had...
IF you intend to install the planearound 180 mechanism,
do it before attaching the two parts

Oren

Good advice. I just did this as well and installed center mechanism before bonding the shells together.

If you do this you need to ensure that there?s no way for the resin from the parabeam in the elbow pocket above to end up in the gearbox. I copied a suggestion of Adrian Port and glued a thin scrap of al across the top of the gearbox with some flox to direct any wayward resin away from the gearbox workings.

Ditto what was said above about the alignment dimples.

I did the same. Since a pic is worth 1,000 words, thought I'd post a couple of this suggestion.

Good advice. I just used some strategically placed packing tape with success.

Larry

That’s a good idea. I tried to be diligent in making sure any strands of parabond didn’t extend down into the gearbox area, but I’ll probably have to clean up a little bit inside when I put the gearbox back in.

Thanks for this advice. I have the Plane Around 180 deg. kit in-hand but haven't reviewed the installation information yet. I would not have thought to install the gear box prior to joining the door halves. Thanks!