| I ran into an unexpected problem. when I attempted to remount the pilot door, I encountered some interference. It was coming |
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| from the gas strut support bracket. I have it mounted such that it projects up into the door hinge recess area, and when I covered |
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| them w/ fiberglass, it wouldn't allow the door to close fully, So.... as a stop gap, I got the Dremel out and cut an opening in the |
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| close out area big enough to allow the door to close fully. I spent Wed night noodeling on a fix, and determined that if I used |
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| shorter screws (still leaving 3 threads showing) I should have enough room to fabricate a contoured close out that will still allow |
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| for a seal with the door seal, and also make enough room for the gas strut bracket. So Today (Thurs) I popped off the copilot |
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| door, installed the nutplates on the hinges, and then used the same process as before (duct tape) and layed-up some 6 ply |
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| pieces. Only for the aft hinge area, I used smaller pieces of duct tape to create the contour and recess for the bracket. When |
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| they cured, I trimmed them to fit, and floxed them in place. Before filling w/ Metal Glaze, I test fit the door to see if the bracket will |
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| clear and for the most part it does, there is a small amount of contact on one side of the bracket, and I'll modify the |
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| cover/close-out tomorrow to handle that. |
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