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<\/a>These photos show the lower left and right corners of the passenger door.\u00a0 This was the hardest area to build up.\u00a0 The default J-channel was very irregular, varied in thickness and sanding in the corners was difficult.<\/p>\n<\/p>\n
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<\/p>\n <\/p>\n <\/p>\n <\/p>\n LATCH MECHANISMS<\/p>\n The exterior door handles provided by Van’s extend quite far from the door surface.\u00a0 After long deliberation I opted for the AeroSport low-profile handles.\u00a0 This requires modification of the latch pockets, but now is the perfect time as the doors are not finished anyway.<\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n AILERON PUSHRODS<\/p>\n My first attempts at making the aileron pushrods did not turn out very well.\u00a0 So I reordered the parts and tried again…<\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n","protected":false},"excerpt":{"rendered":" The slow process of applying filler and sanding on the doors, frames and canopy finally has an end in sight. Much of the time was preparing the door frame J-channel for accepting the McMaster-Carr weatherstrip molding.\u00a0 My intention was leave as much of the original canopy material in place as possible, just relieve enough for …<\/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-2360","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\/2360","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=2360"}],"version-history":[{"count":12,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts\/2360\/revisions"}],"predecessor-version":[{"id":2399,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=\/wp\/v2\/posts\/2360\/revisions\/2399"}],"wp:attachment":[{"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=2360"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=2360"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/rv10.mirimar.org\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=2360"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}<\/a>After getting the doors to an intermediate fit, off came the doors and hinges.\u00a0 The intention is to send out the hinges for chrome.\u00a0 However, the steel finish as provided from Van’s is pitted or marred with milling marks.\u00a0 The portions which will be most visible after installation were hand sanded and polished. Hopefully this preparation step will lead to a better final look in chrome.<\/p>\n<\/a><\/a>Another set of fabricated items for the doors are hinge spacers for the Bansbach gas-struts, and bracket locating bars made from 3\/8″ plywood.\u00a0 These bars will be used to properly set the distance from the AirWard strut brackets to the hinges on the inner door panel.<\/p>\n<\/a>This photo shows a thin metal striker plate will be fabricated to accept the modified Delrin block to hold the standard latch gear and accommodates an integrated lock mechanism. This requires boring out a larger hole for the handle lever and a pass-through for the lock body.<\/p>\n<\/a>The right photo shows the passenger door being modified for the larger lever body and lock hole.<\/p>\n<\/a>After the modification, the fiberglass around the lock is quit thin.\u00a0 Now I see why a plate of reinforcing steel is needed.<\/p>\n<\/a>The lock does fit well, though maybe a lock with a shorter body would be better.\u00a0 Why – the Phillips screw holding the locking lever extends above the surface of the door interior.\u00a0 This would make fabricating a vanity or cover plate difficult.<\/p>\n<\/a>This picture of the initial rods show how the rivet hole is chowdered badly from the drill press.\u00a0 The rod was not secured properly and moved drastically during the process. My bad.\u00a0 The rod was being held in a drill vise with the end sticking out, no support provided on the outer end to take the pressure and keep the rod from bending.<\/p>\n<\/a>At least two lessons were learned from the previous exercise:\u00a0 measure twice…\u00a0 and make sure the part is properly secured when drilling.\u00a0 In this photo shows measuring the 48″ rod to ensure there is sufficient room at the end to fit into a precision V-block on both sides of the drill location.<\/p>\n<\/a><\/a>After spot drilling (lesson 3 for small diameter rods, keeps the drill from wandering on initial contact) the separate inner holes are drilled.\u00a0 Note the V-blocks on each side.\u00a0 The rod was then cut in half and the two pushrods were adjusted by hand filing to 21 – 11\/32″ length.<\/p>\n<\/a><\/a>The drill results are very good.\u00a0 The insides need to be primed, then all the through rivets will be inserted.\u00a0 The right photo shows a end of each rod with one rivet.\u00a0 Nice tight fit and no wiggle in the threaded ends.<\/p>\n