Quote:
Originally Posted by CharlieWaffles
Any info, photos or details for retrofitting this into an existing door? Wondering what has to be modified, removed, drilled to make these work.
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Mark,
I installed the existing handles with the Planearound third door latch first before installing this new handle. I also had the Planearound guides and latch sealed in with fiberglass prior to the test install.
To modify an existing door the existing handle mechanism needs to be removed to cut back the internal handle tube and it's internal pin. The Delrin block is replaced with a new one. The door hole you cut for the Vans handle is opened up to a larger diameter and an additional hole is drilled forward of that for the lock. All of this is covered up with that external ring in the end. Then the handle is reassembled in the pocket and screwed back into place.
If you have sealed in your external screws, things could be a bit tricky, but its not impossible. This is just a suggestion for someone in that particular situation. This is untested so I have no guarantee that it would work. But I would suggest drilling out the rivets that hold the nutplate to the internal plates (the one that is turned upside down for your external screws) then you can turn the nutplate to remove it allowing you to then remove the internal workings. Do the work on the door, like I mentioned above, then reassemble. The internal plates (C-1006A, B, D) are reused in this design. After assembly, screw the nutplate back on and use pop rivets to hold it in place.
I have written complete instructions for the install including a lot of pictures. I don't know if Aerosport is wanting to release the instructions yet, but you could give them a call. It wouldn't hurt ask.
P.S. You did a beautiful job on your plane!...I check out you blog for insight on a regular basis.
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