Oil door fit

[Dorfie]

I want to "mould" the oil door into the cutout for the oil door in the top cowl. It fits pretty well but the gap around edges is too big and I would like the door to rest firmly in the cutout lip to minimize cooling air lost (RV10).
Can anyone tell me how to get an even gap (about 1/16" that will allow for paint) around the perimeter of the door.
The edge is just too thin for insulating tape to stick (what I was planning to use).
Planning on using clear packing tape on inside of oil door to prevent resin sticking.
If I use PVC, can that be removed later to make resin stick to the oil door at later stage? If yes, how?
Thanks.
Johan

[ChiefPilot]

There are multiple ways to get the result you're after - my approach was to fill the cowl opening so that the door was a perfect fit, then slightly reduce the door size by sanding to get the perfect gap. I started with this:

...and ended with this:

More pictures on the entire process are on my flickr photo album.

[BillL]

Originally Posted by Dorfie

I want to "mould" the oil door into the cutout for the oil door in the top cowl. It fits pretty well but the gap around edges is too big and I would like the door to rest firmly in the cutout lip to minimize cooling air lost (RV10).
Can anyone tell me how to get an even gap (about 1/16" that will allow for paint) around the perimeter of the door.
The edge is just too thin for insulating tape to stick (what I was planning to use).
Planning on using clear packing tape on inside of oil door to prevent resin sticking.
If I use PVC, can that be removed later to make resin stick to the oil door at later stage? If yes, how?
Thanks.
Johan

Just use some non stick tape, epoxy/fill the gap with the door in place and don't worry about the end point gap, it can be controlled by sanding of the door.

OK - Like ChiefPilot says - and he has pictures!!

[rvbuilder2002]

Originally Posted by ChiefPilot

There are multiple ways to get the result you're after - my approach was to fill the cowl opening so that the door was a perfect fit, then slightly reduce the door size by sanding to get the perfect gap. I started with this:

...and ended with this:

More pictures on the entire process are on my flickr photo album.

I think this is the easiest and is the way I do it.
Though I use flox instead of micro so that the molded sharp edge is hard and durable. A little harder to sand but a small amount can be used and then do the blending with micro if needed.

[Dorfie]

To all the responders, thank you. I now know what to do.
Brad, that oil door fit is really beautiful.
Johan