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These doors may be the death of me…

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flywithayres

Well Known Member
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The doors are killing me. It doesn’t help that I’ve added the PlaneAround center cam and the Aerosport low profile handles, but it’s some of the stock things that are frustrating me.

Do nutplates really work in the reverse? The instructions show assembly of the latch mechanism plates. The latch assembly is then held to the door with AN509 screws that thread through the nut plates from the backside.
I can’t for the life of me get them to seat when assembled to the doors. They just won’t catch the threads. The screws are long enough. I’ve pre run them before assembly. I’ve even tapped the nut plates from the back. Did this step challenge you or am I doing something wrong? Any thoughts?

Thanks.
 

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I had custom door handles, so never did this. I would run the tap through the front side and be sure you take the tap ALL the way through until it spins loosely, like a screw does. It is possible you got them a bit off parallel by starting from the other side. Taps need to go a good way up the thread to get the final cutting and you will need that in this case. Will also need good alignment. With stacked up holes, it is possible that the screw is getting pushed slightly into an angle or offset, causing the starting issue. Installed this way, you don't get that dish to help push the screw into the threads.
 
I did think it odd that the nut plates are reversed but it didn't cause a problem for me. I assume the screws will go into the nut plates if you run them in the normal direction? If they do, it suggests some misalignment between the holes in the door skin and the nut plates.
 
I remember I had to use my deburr tool to widen the hole in the plastic part to get everything to sandwich nicely together.

I just finished the doors (well, I'm about to glue the second window on the second door and then I'm really done). At times I wasn't sure that I'd ever finish them. But after I was done I found out that somebody has made a consolidated installation manual that merges the Van's instructions, the PlaneAround instructions, and the AeroSport instructions. You can find it linked near the top of the wiki here:

SECTION 45: CABIN DOORS & TRANSPARENCIES - RV10 Community Wiki

rv10.org rv10.org

I also put a lot of effort into expanding that Wiki page, so if you haven't seen it recently definitely take a look at those instructions and the rest of the wiki. But it is all possible -- as I mentioned, I now have finished doors with the following:
  • PlaneAround Center Cam
  • PlaneAround hinge pins and blocks
  • Aerosport interior and exterior handles
  • Locks in both doors
  • McMaster door seals
  • SilPruf windows
  • Interior paint
My total time on the doors was 106 hours not counting the windows and interior paint. I'm up to 40 hours on the windows but I'm not quite done yet.
 
Thanks for the help, all. I tired the reamer through the front and it worked. Much appreciated.

@kirkbauer Did you have any issues with the PlaneAround push rod contacting the cam housing before the Aerosport handle reached the full closed (fwd) position? I was so happy to get everything connected only to discover that latest challenge. The cam housing is exactly where the directions specify.
 
flywithayres said:
@kirkbauer Did you have any issues with the PlaneAround push rod contacting the cam housing before the Aerosport handle reached the full closed (fwd) position? I was so happy to get everything connected only to discover that latest challenge. The cam housing is exactly where the directions specify.
Click to expand...
If the cam is installed in the right location, what about the door handle gear assembly? The Plane Around is designed to fit with the door handle assembly in the location indicated in the Vans instructions. If you moved that to better center it with the Aerosport handle assembly and lock, then the Plane Around push rods will not be the right length. (Don't ask me how I know :oops: ).
 
DRMA said:
If the cam is installed in the right location, what about the door handle gear assembly? The Plane Around is designed to fit with the door handle assembly in the location indicated in the Vans instructions. If you moved that to better center it with the Aerosport handle assembly and lock, then the Plane Around push rods will not be the right length. (Don't ask me how I know :oops: ).
Click to expand...
I reviewed the photos and it seems to be in the appropriate spot. The Van’s instructions show it centered in the recess which tracks with the Aerosport strike plate alignment. 🤷‍♂️
What was your fix? Shorten the lower rack?
 
Sounds like the rails/gears need to be clocked differently. I remember going through many iterations before finding the exact right gear-tooth mesh combination.
 
flywithayres said:
I reviewed the photos and it seems to be in the appropriate spot. The Van’s instructions show it centered in the recess which tracks with the Aerosport strike plate alignment. 🤷‍♂️
What was your fix? Shorten the lower rack?
Click to expand...
I ended up measuring for the length and then paying Plane Around to mill some custom rods to fit. Once the right length rods were in place, everything works great.

If I recall correctly, the aerosport plate alignment is not centered in the door pocket, and my problem was that I centered it. The door lock cylinder causes the aerosport plate to be a bit off center if you install it with the handle rod in the hole location specified in the Vans instructions.

The intent of the Aerosport handle is to be installed after the door latch is installed with the Vans parts & handle. and the plane around is also designed for the Vans specified location. The problem occurs when a builder like me decides to install all 3 different systems at one time in order to avoid rework, and places the Vans handle mechanism in a slightly different position, which is what caused my problems.
 
Understood. Thanks.
I’ll try to reclock and hope for a little luck. I’ve only been getting one good day per week in the hangar since the training dept has owned me the last six weeks. That makes it hard to get any focused continuity. But, that’s all done and as of Sept 1, I’m back on reserve and will be waiting for a call from the hangar with a packed bag and uniform in the car. Here’s hoping some progress will be made.
 
kirkbauer said:
I remember I had to use my deburr tool to widen the hole in the plastic part to get everything to sandwich nicely together.

I just finished the doors (well, I'm about to glue the second window on the second door and then I'm really done). At times I wasn't sure that I'd ever finish them. But after I was done I found out that somebody has made a consolidated installation manual that merges the Van's instructions, the PlaneAround instructions, and the AeroSport instructions. You can find it linked near the top of the wiki here:

SECTION 45: CABIN DOORS & TRANSPARENCIES - RV10 Community Wiki

rv10.org rv10.org

I also put a lot of effort into expanding that Wiki page, so if you haven't seen it recently definitely take a look at those instructions and the rest of the wiki. But it is all possible -- as I mentioned, I now have finished doors with the following:
  • PlaneAround Center Cam
  • PlaneAround hinge pins and blocks
  • Aerosport interior and exterior handles
  • Locks in both doors
  • McMaster door seals
  • SilPruf windows
  • Interior paint
My total time on the doors was 106 hours not counting the windows and interior paint. I'm up to 40 hours on the windows but I'm not quite done yet.
Click to expand...
How did you get the Aerosport interior cover to fit? It appears that it will not allow enough room with the lock installed?
 
howardtlcc said:
How did you get the Aerosport interior cover to fit? It appears that it will not allow enough room with the lock installed?
Click to expand...
Yeah, I was lucky to have found this post (which I have just recently added to the Wiki):

Aerosport Door Handle Cover Issue

Installing my doors tonight and went to put on the Aerosport interior door handle cover plate. I had already fitted it to the door, but once the lock was installed, the plate won't fit flush due to it hitting the locking tab and screw. Anyone else have this issue? If so, curious to know...
vansairforce.net

Once you trim all of the marked areas, the plates fit perfectly over the lock.
 
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