One piece Lexan Door

For general discussion of the Just Aircraft family of aircraft.
Includes: Highlander, Escapade, Summit and SuperSTOL.
FredHoffman
Veteran Member
Posts: 136
Joined: Fri Mar 23, 2012 8:57 pm

Re: One piece Lexan Door

Post by FredHoffman »

Just finished the doors with one piece of lexan. I made a cut at the back of the door so it would contour to the frame. The cut goes from the high point on the center support to the rear. It would be possible to overlap the pieces but I cut it so they were butted next to each other then added a trim piece to hold them down securely. It might be possible to have a smaller cut but I don't think it would follow the frame and would stand off a bit.
You do not have the required permissions to view the files attached to this post.
User avatar
gkremers
Veteran Member
Posts: 495
Joined: Sun Aug 08, 2010 8:06 am
Location: Michigan

Re: One piece Lexan Door

Post by gkremers »

Fred,
Really nice job. When it comes time to change out the Lexan This looks like a good option.

Gary
User avatar
Tralika
Veteran Member
Posts: 385
Joined: Thu Oct 08, 2009 12:49 pm
Location: Wasilla Alaska

Re: One piece Lexan Door

Post by Tralika »

Fred,
Thanks for posting the photos of your door mod. It's a nice solution to the overlapping plex.
John Nealon
Wasilla, Alaska
Highlander Extreme #191
mykitlog.com/jnealon
FredHoffman
Veteran Member
Posts: 136
Joined: Fri Mar 23, 2012 8:57 pm

Re: One piece Lexan Door

Post by FredHoffman »

version 2.0. I thought the trim piece was too big.
You do not have the required permissions to view the files attached to this post.
User avatar
BDA
Veteran Member
Posts: 707
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: One piece Lexan Door

Post by BDA »

I got around to building doors - Tried the "one piece lexan" - thanks Fred!

I drilled a stop hole where the middle tube makes its bend about 14" in from the rear edge, then cut the lexan from the edge to the hole.
Then drilled it to overlap but it looks terrible, so I will trim for a butt joint with a small splice piece of lexan and VHB tape.

Is anyone using edge trim on the lexan where it contacts the fabric?
You do not have the required permissions to view the files attached to this post.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
User avatar
Tralika
Veteran Member
Posts: 385
Joined: Thu Oct 08, 2009 12:49 pm
Location: Wasilla Alaska

Re: One piece Lexan Door

Post by Tralika »

I did not overlap the the lexan where it joins together. I carefully cut the two sides so they butted together tightly and secured them with the large head aluminum rivets. I didn't see a need for the trim to cover the joint. I've flown the plane 100 hours with and everything is still tight. My doors are the old style welded round tubing which may be different than yours. I used the 3M 8672 black tape to protect the fabric on the bottom and rear of the door. I used the 3M 8672 clear tape to protect the paint on the front of the door. The lexan does rub on those surfaces so you need something to protect it.
You do not have the required permissions to view the files attached to this post.
John Nealon
Wasilla, Alaska
Highlander Extreme #191
mykitlog.com/jnealon
User avatar
BDA
Veteran Member
Posts: 707
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: One piece Lexan Door

Post by BDA »

Thanks John!!

You should come down to the farm and give me some pointers!
60*32'58"
151*05'11"
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
User avatar
Tralika
Veteran Member
Posts: 385
Joined: Thu Oct 08, 2009 12:49 pm
Location: Wasilla Alaska

Re: One piece Lexan Door

Post by Tralika »

It doesn't look like you need any pointers but maybe I'll drop in when I get back in the spring. I've got a few projects I'm going to finish up on my plane when I get back. Hopefully the weather this May is better than last year.
John Nealon
Wasilla, Alaska
Highlander Extreme #191
mykitlog.com/jnealon
User avatar
BDA
Veteran Member
Posts: 707
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: One piece Lexan Door

Post by BDA »

YES!
Hope weather is better soon - Snowing like crazy all week.
Road to anchorage was closed all day yesterday so they could shoot the avalanche guns.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
User avatar
BDA
Veteran Member
Posts: 707
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: One piece Lexan Door

Post by BDA »

Well...
I used the VHB tape to put one side door glass on.
It did not go well...

Have you ever used a step stool to take down that sticky fly tape, and stepped down off of it with the tape held as far away from your body as possible, and stepped right on a leggo? And land full on in the fly tape, while desperately flailing the other hand to try to keep the crunchy ones out of your mouth as you scream four letter words about the makers of legos?

It was like that.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
User avatar
SheepdogRD
Proprietor
Posts: 930
Joined: Tue Nov 30, 2010 5:41 pm
Location: West of Atlanta, GA

Re: One piece Lexan Door

Post by SheepdogRD »

BDA wrote:I used the VHB tape to put one side door glass on. It did not go well...
Here's the trick to VHB tape: Apply the tape wherever you need it to go. Leave the protective film on it. On each piece of tape, strip a little of the protective film and bend it out 90 degrees to form a pull tab you can access after final positioning of the Lexan. If you're working from the center to the ends, make pull tabs in the center of the tape. Reinstall the Lexan using clecos. Pull the VHB tabs and install your final fasteners as you go along.

If you're working barefoot, don't leave Lego blocks in your workspace. Them suckers hurt.
Richard Holtz
Highlander N570L -- Ms. Tonka -- in gestation

If just enough is really good, then too much ought to be perfect.
User avatar
BDA
Veteran Member
Posts: 707
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: One piece Lexan Door

Post by BDA »

Ya, I think with the round tubing the 1/2” wide tape is way too much.

I tried to cut strips, Nope
I thought I would just trim it off after - Nope

This stuff must be what they use on those glue board traps.

My tools are stuck in it, my hair, my legos...
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
User avatar
BlainS
Seasoned Member
Posts: 50
Joined: Fri Aug 07, 2020 4:45 pm

Re: One piece Lexan Door

Post by BlainS »

Has anyone tried to bond the lexan to the frame with Sikaflex? Common practice in the Vans RV ships. Used it to bond the canopy of my RV-8 and couldn't be happier.
User avatar
gkremers
Veteran Member
Posts: 495
Joined: Sun Aug 08, 2010 8:06 am
Location: Michigan

Re: One piece Lexan Door

Post by gkremers »

The Vans canopies are formed and much thicker than the lexan supplied with the Just kit. The doors and windshield (at least on the Highlander) are flat sheets and under a good pre-load. The material is also easily scratched so plan on changing them out every so often unless you don't mind scratches. You could probably use the Sikaflex but not sure it's going to be worth the effort.

Gary
User avatar
mhcrowder
Veteran Member
Posts: 183
Joined: Sat Aug 28, 2004 9:18 am
Location: Cary, NC
Contact:

Re: One piece Lexan Door

Post by mhcrowder »

It would be nice if there was a preformed Lexan sheet for the Just doors without windows. I've never linked having to cut the door into two pieces or cutting a wedge out like some have done.
Building Highlander #371
http://highlander371.blogspot.com/
Post Reply

Return to “Just Aircraft”