- 5.5.1 Install Door Lift Gas Struts
- 5.5.1 Install Door Lift Gas Struts
- 5.5.1 Door Lift Gas Struts
- 5.5.1 Door lift gas struts
- 5.5.1 Install Door Lift Gas Struts
- 5.2.4 Door Hinge Installation (Modification)
- 5.2.3 Door Opening
- 5.3 Door Latch Micro Switches
- 5.3.1 Door Latches
- 5.5 Strake Extension Cutout
- 5.2 Correcting Door Fit
- 5.2.3 Door Fit (Improving)
- 5.3.6 Door Pin Sleeves
- 5.2.2 Door openings
- 5.1.4 Window Scratches
- 5.6 Improving door fit
Now that I’ve got the door lift situation figured out, it’s time to work on the pilot side door. I did the initial work on the co-pilot door since that door won’t get as much use as the pilot side.
Now that I know how the system works, I’m going do the pilot door a little differently. As in stronger. The first thing to do is create a large backing plate/hardpoint out of 1/8″ aluminum.
Then I cut an opening in the top of the D-tube that will accept the plate. I drilled and tapped holes in the plate that will align with the mounting bracket and also drilled holes for rivets. Then I formed the plate so that it matched the contour on the D-tube.
Finally, I spread structural adhesive on the inside of the D-tube and the back of the plate and slid the plate into the D-tube and riveted the plate into position. Once the adhesive set, I inserted a piece of soft foam into the space and left a cavity about 1/2″ deep that a little longer than the opening I made to get the plate in. Then I mixed a flox/cabo paste and filled the area behind the plate. This will strengthen the D-tube where the bracket is.
Once cured, the area gets sanded down and I’ll cover it with a layer of carbon Uni and BID.