This summary covers a long period after Airventure, and prior to Labor Day.
The hinges finally can back after being chomed. The results are good, and primarily based on the degree of preparation sanding I put into them beforehand. Hinge pins are cut to length from stainless steel AN3-21 bolts.
Hinge pin locations are covered with resin, then sanded smooth.
The sand, resin, repeat process took a long time to get the surfaces just right.
Once the doors were ready, a batch of alodined parts was also prepared to prime/paint at the same time.
Tal’s paint booth was used to spray the doors and the parts.
HINGE COVERS
After painting the doors a build of custom hinge covers is needed to provide a good seal to the McMaster weatherstrip. Some modeling clay was used to partially fill the hinge pockets.
Then a few sheets of fiberglass were prepared, then pressed into position while still flexible. Fitting and flush mounting remain after the sheets dry.
OVERHEAD CONSOLE / GPS ANTENNA MOUNT
I would like to have the GPS antenna for the Garmin GTN650 located under the canopy. However, the antenna attachment is too deep to fit in the gap between the canopy and the overhead console. A custom cover was procured via 3D printing from AeorSport Products.
A mounting platform for the antenna itself was made from spare aluminum angle and sheets.
The platform is hinged, so exact angle with airplane centerline and flight angle can be achieved.
The hole for the custom cover is fabricated in the rear access panel.
Here is the final test fit showing the configuration of the cover, mounting bracket and antenna. Once the console is bonded to the canopy, the bracket can be permanently installed.