{"id":2307,"date":"2018-02-08T15:04:51","date_gmt":"2018-02-08T20:04:51","guid":{"rendered":"http:\/\/rv10.mirimar.org\/?p=2307"},"modified":"2018-02-08T15:29:43","modified_gmt":"2018-02-08T20:29:43","slug":"cabin-doors-2","status":"publish","type":"post","link":"https:\/\/rv10.mirimar.org\/?p=2307","title":{"rendered":"Cabin Doors (2)"},"content":{"rendered":"

Over the past few weeks, many distractions for home improvements have gotten in the way of progress on the plane.\u00a0 However, a recent visit from Rich has helped put wind back in the sails.\u00a0\u00a0My approach\u00a0was to\u00a0finish as much work\u00a0on the latches, gear boxes, pin blocks and other accessories\u00a0prior to\u00a0bonding the inner and outer shells together.\u00a0 Made for much easier access to some tight areas.<\/p>\n

\"\"<\/a>\"\"<\/a>Here the Delrin pin blocks from PlaneAround are being shaped with a vixen file to match the corresponding door pockets.<\/p>\n

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\"\"<\/a>\"\"<\/a>Next action is bond on fiberglass reinforcement squares from the PlaneAround kit around the center gear box.\u00a0 A cover\u00a0plate was fabricated to cover the\u00a0cam shaft slot opening on the inner\u00a0door panel.\u00a0 This\u00a0is not required for structural reasons, but should add a finished look.<\/p>\n

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\"\"<\/a>\"\"<\/a>\"\"<\/a>The default Van’s pins are bent, measured and cut in preparation for adding stainless steel and machined PlaneAround pin tips.<\/p>\n

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\"\"<\/a>\"\"<\/a>The pins are cut to approximate length, but must be hand filed for the machined pin face to be oriented correctly.\u00a0 When done right, the pins should pull the door down and in when engaged.\u00a0 The pin is tapped for a 3\/8-24 bolt which is\u00a0tapered slightly for easy insertion.<\/p>\n

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Rich confirmed proper geometries and alignment of the latch parts, then began preparing to apply foam for sound dampening.<\/p>\n

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\"\"<\/a>The last step before bonding is shave the foam flush with the inner surface.\u00a0 The shells edges were sanded and test fit to ensure no excess foam interfered with smooth surface contact.<\/p>\n

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BONDING PROCESS (over a few days duration) ================<\/p>\n

\"\"<\/a>\"\"<\/a>Over at the rented shop, the right\u00a0side is covered with plastic to prevent extra adhesive from squeezing out the edges onto the canopy.\u00a0 Then West System epoxy is mixed together.\u00a0 A batch of ‘neat’ (no fillers) with three pumps resin and three pumps hardener\u00a0was prepared to wet both shell surfaces.<\/p>\n

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\"\"<\/a>\"\"<\/a>Here the elbow pocket is covered wet before application of a 5 x 9 inch piece of Permabond (triple layer fiberglass mat).\u00a0 The mat\u00a0was thoroughly soaked in neat adhesive.<\/p>\n

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\"\"<\/a>This photo shows wetting the cranial cavity on the inner shell.\u00a0 This area was treated with the same Permabond as for the elbow pocket. After this operation, I had an issue with the bonding material used for the right door outer edges (more on that later)…<\/p>\n

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\"\"\"\"<\/a>When done properly bonding the outer edge used three separate\u00a0batches of three pumps each of\u00a0resin\/adhesive first mixed together, then stiffened with six spoonfuls of West 406 (colloidal silica).\u00a0 The consistency turned out similar to peanut butter.\u00a0 The final adhesive mixture\u00a0was spread about 1\/16″ evenly on each surface before mating together.<\/p>\n

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\"\"<\/a>\"\"<\/a>Clecoes hold the lower section to the fuselage through witness holes.\u00a0 Clamps have been applied to the sides along the door channels.\u00a0 Sandbags about 25 pounds each and other extra weights hold the top section in place.<\/p>\n

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\"\"<\/a>Rich had the good idea of using kraft sticks to distribute the clamping pressure along the door edges.\u00a0 A firm, uniform\u00a0clamping force\u00a0is desired.\u00a0 Too much pressure causes the adhesive to be forcefully ejected from the bonding location – effectively ‘starving’ the joint and causing a weaker bond.<\/p>\n

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\"\"<\/a>Here\u00a0is photo from a different day of the left door clamped onto the canopy to cure.\u00a0 The recommendation is allow 24 to 48 hours to harden before removing.\u00a0 This lets the\u00a0door permanently shape to the contour of the canopy.<\/p>\n

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\"\"<\/a>\"\"<\/a>The\u00a0bonded door shells are very tight, no fear of\u00a0delamination here!\u00a0Now begins the process of trimming the shells to final dimensions.\u00a0 First the window frames, then the door edges to match the frame openings.<\/p>\n

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Confession time:\u00a0 On the right door I mistakenly used sealant instead of fiberglass adhesive on the outer edges.\u00a0Fortunately I was able to completely remove the sealant before proper application of the epoxy adhesive.\u00a0 Overall the final outcome for both doors was very good and structural integrity is preserved.<\/p>\n

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Over the past few weeks, many distractions for home improvements have gotten in the way of progress on the plane.\u00a0 However, a recent visit from Rich has helped put wind back in the sails.\u00a0\u00a0My approach\u00a0was to\u00a0finish as much work\u00a0on the latches, gear boxes, pin blocks and other accessories\u00a0prior to\u00a0bonding the inner and outer shells together.\u00a0 …<\/span> Continue Reading →<\/span><\/a><\/span><\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[10,52],"tags":[],"class_list":["post-2307","post","type-post","status-publish","format-standard","hentry","category-rv-10-build-project","category-section-45-cabin-doors-and-transparencies"],"_links":{"self":[{"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts\/2307","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=2307"}],"version-history":[{"count":5,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts\/2307\/revisions"}],"predecessor-version":[{"id":2312,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts\/2307\/revisions\/2312"}],"wp:attachment":[{"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=2307"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=2307"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=2307"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}