Doors

[b1x4nqb]

Any advice on cutting the lexan oversize for the doors.  I followed the book today but when I went to bend it over the door frame it comes up short in covering the entire frame.  It is very stiff in wanting to bend over the frame anyway.  Sort of bending it down over the center section then forward as well around the bend in the center section.  Does that make sense??  Anyway, did you all use the book recommended 1 inch overlap on the bottom and rear for the door frame or go larger?

I might order thinner stuff.  Doors are not required on this plane for the DAR inspection, are they?

Thanks,
Paul

[rmullins]

We went larger than the instructions specified, especially in the front. Its nice to have enough to make a good seal to keep out the drafts, you can really appreciate that this time of year.

I took Troys advice and ditched the top window. If you're on the ground and it's too hot, open the door....

[KevinC]

I cut everything initially very oversize, then drilled/cleco'd the panels starting from one end to the other, then I put the doors in place to see how much to cut.  I was amazed how much extra I needed past the frame.  I had no problems with the bends.

fwiw

k

[Dave Krall CFII SEL SES]

I cut everything initially very oversize, then drilled/cleco'd the panels starting from one end to the other, then I put the doors in place to see how much to cut.  I was amazed how much extra I needed past the frame.  I had no problems with the bends.

fwiw

k

We went well oversize and added leading edge door edge protectors like Taildraggerfun's plane shows.
We also cold-bent the forward corner of Lexan inward with 4" break pliers.

[Roger]

Hey Dave:
Did you let the window Lexan, overlap the aluminum piece at the top front? I haven't installed (except to fit) the doors yet, and I allowed about 1" overlap on that aluminum piece. Just wondered if I should trim it off or leave it overlap.

[scubarider2]

Paul, yep I did the same as everyone it seems.  I cut it with generous overlap then fit it to the frame.  Then after holding it up on the plane drew with a marker where I needed it cut just right so that the overlap would seal and not just at the door.  I left the window in because I can open it in flight.  Great way to cool it down and bring in some fresh air.  I also open it during taxi.  If you cut enough overlay in the window it is no problem with air coming in during the winter months.
Dennis

[taildrgfun]

We open our windows in flight almost every time we fly.  I can't imagine not having them for ventilation and photography.  Another thing I like doing is blowing up a balloon, throwing it out the window and then circling around and breaking it with the prop.

[KevinC]

Unfortunately I still don't know how it will work - but here's how I protected the leading edge of the door from the slipstream.  It is made from a 2" wide piece of aluminum.

fwiw

k

[Dave Krall CFII SEL SES]

Hey Dave:
Did you let the window Lexan, overlap the aluminum piece at the top front? I haven't installed (except to fit) the doors yet, and I allowed about 1" overlap on that aluminum piece. Just wondered if I should trim it off or leave it overlap.

Hi Roger,
I have the Lexan overlaping the metal piece by about 3/8" right now. It's a tight seal but I very well may trim it so that it comes inside the metal and out of the slipstream.