| I pretty much finished the cabin/door hinge covers today. I previously completed the right aft cover as a test/experiment. So |
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| today, I cut, trimmed and sanded the lay-ups for the other 3 covers and then proceeded to Dremel route the cabin cover for |
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| them. Same procedure as the previous, 1st I positioned each cover, traced it with a Sharpie fine point pen, then using a Dremel |
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| w/ a 'router' bit to route out about 3/64" of the cabin cover to allow for the hinge covers to be recessed, I did this by hand and |
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| trued up the edges using a file. Each hinge took about 45-60 minutes to do the routing. Then marked the covers for the #6 |
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| attachment screws and match drilled those into each hinge. Tapped each hinge using a 6-32 tap (I actually wore one out and |
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| had to use a second one to finish as the initial holes were undersized) Then I epoxied some standoffs onto the bottom of each |
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| cover and did a tet fitting of each cover, using a sanding block to even up the sides. The reaf/aft covers required a thin washer |
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| on the outboard screw, but the others were good with just the nylon standoff. With all of the covers mounted, I measured and |
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| marked each for the slot for the portion of the hinge to move through when opening, used a dremel to cut the openings, |
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| filed/sanded them, and remounted and final fit the covers. Tomorrow I'll prime them and they wiil be paint ready. (I wish I knew I |
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| was going to do this and I could have saved myself 5-10 hours of unnecessary finish work on the hinge openings!!!!! |
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