(19) Doors ( Mike )

[planecrazzzy]

Hey Guys,
Seems there's a little bit to these doors...

First , the upper part of the door frame , is not on the prints.

In order to get this "right".... I needed to push the plane out , and set up the wings....

This was the only way to get it exact.... I had some "guess" lines that were close....

But I didn't want the tube too low or too high...

I will post a measurement from the bottom of the fuselage , to show where the tubes belong...

Then... They can be installed from the beginning , when the fuselage sides are built...
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Here's the plane outside , getting the exact position for the tube...
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Gotta Fly...
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[planecrazzzy]

OK,
Door frame tube is in place...

The Hinges are a Grey area.... and I really don't like the upper door hinge...

Looking at Earl's building pictures , I don't think he has the doors sealed very good....

I'm changing my hinges.... ( I'm changing the whole door )

Also , I will be "Skinning" my door with 6061 T6 Aluminum... , which will overlap the frame...

and should get a tight seal around the door....

The Tailwind door is made in the door frame , with 1/8" shims all around it....

I did this at first.... But later found I needed to raise the lower tube , to weld a "weldnut" at the bottom door hinge....

After I made both doors... I installed "one"..... I needed to push the plane outside AGAIN...

in order to see if the door would "clear" the bottom of the wing.....

I have 1-1/2" dihedral in my wings.... But the door "rises" when opened....

I put it together and checked it.... it works , Barely.....

Here's some pictures...
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Gotta Fly...
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[planecrazzzy]

mo pix

[planecrazzzy]

mo pix

[planecrazzzy]

mo pix

[planecrazzzy]

The Bottom "Hinge Bolt" , doesn't have a way to keep it from coming out....

I welded some little scrap pieces , with holes drilled into them...

I will be able to put a loose safety wire on the head of the bolts....

The top of the door will get a nylock nut....
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Gotta Fly...
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[planecrazzzy]

Hey Guys,
Next step was to put "door stops" in place....

After those were in place , I was ready to make the door handles and a door latch...

I have a very simple and light system....

There's a key lock on the pilot side...

and a self locking mechanism on the passenger side.

This was mostly made out of Stainless Steel

Here's some Pix
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Gotta Fly...
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[planecrazzzy]

mo pix

[planecrazzzy]

This is my "Auto" lock on the passenger side....

I was going to put "just" an inside door handle.... But I thought that would give me problems later...

If I need to work on the passenger side.... I'd need to go around to open the door...

This system will auto-lock the door....

But a toothpick can also be used to hold it and keep it from locking....

or the screw will come out.... and it can be removed...
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Gotta Fly...
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[planecrazzzy]

In these photo's , you can see the door "stops".... Three type...

The top one , just "flat stock" with some holes... it can be "tapped" with a hammer for fine tuning....

The bottom one has a screw that can be adjusted... ( once the door skin is on )

The third "stop" , is a MIG welded bead .... coated with Silicone Bronze....

This one keeps the door from sagging , which will help a tight fit on the door skin to front/side panel match up ...
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Gotta Fly...
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[planecrazzzy]

Hey Guys,
I'm also modifying the door skins... I'm doing it more like most Tailwinds ... Aluminum...

I used .032 6061 T6 , because it's what I had..... Thinner would be better...

Also , to save on Aluminum , I'm making "sections".... The lower door skin is one piece.

The upper frame around the window , is made from three pieces...

I welded the upper three pieces , but it'll stay separate from the lower skin....
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Gotta Fly...
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[planecrazzzy]

Next, I fit the lower skin and added cleco's to keep it in place...

Then I fit the two vertical pieces for the frame , getting a good match up to the lower skin...

After , I fit the top frame pieces , I put some cleco's in them to hold during welding....

After I welded to top pieces together , I ground them flush and ran them through the English Wheel

also , I needed a little extra work with the English Wheel to help alien the rivets again....
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Just a note , I made my frame pieces a little big.... After welding , they were sheared to size...
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. Gotta Fly...
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[planecrazzzy]

After the upper window frame was welded , cleaned up , and trimmed....

The lay-out for the radius was done.... The side window pieces were cut wide to accommodate this....

The radius was done with a spray paint "Cap".... I looked at a 2 inch radius , but it was small....

The cap was about 2-1/2" or more....
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Gotta Fly...

[planecrazzzy]

Since I modified my doors , they open different....

In fact , the front of the door moves "inside" .....

So I used my "Beader" , and formed a lip on the edge of the door skin....

The forward fuselage skin will over lap this for a good seal... ( see example )
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Gotta Fly...
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[planecrazzzy]

This is a good time to show a little tool I made to help find "center" of the tube for drilling....

If the hole in the tube isn't exactly center , it's gonna warp the skin.....

For the 1/2 inch tube , I was measuring the skin "To the Tube"... then adding 1/4 inch...

"Close" , but not close enough , this jig helps "Nail it"
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I thought I was making this for drilling 1/2" , 5/8" and 3/4" tubes

Oooops , I goofed .... it fits 1/2" , 3/4" and 1" ( Oh well...)

I tried the jig , it works great.... Just watch the angle , it needs to be in line with the skin....
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To get an accurate spacing before welding it , I put an 1/8" bit in the hole , and used a 3/16" bit for a spacer...

I clamped it using two thickness's of skin ( 1/16" total )... Welded it and let cool before taking the clamp off....
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Gotta Fly...
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