9 Nov 08

My engine install kit should arrive tomorrow or Tuesday. So in the mean time, I am working on the doors.
This is the door frame after all the holes are drilled around the edge and the rib for the lexan.
The aft end of the rib is attached to the door frame in a really poor way. I think Rans recognized this too because the following piece I copied from their new factory S-6. This isn't in the manual, but it's a lot nicer way to attach the aft end of the rib.

I cut a triangle out of a scrap piece of aluminum.

Cut it to fit, file the edges smooth, and drill the holes...
Attach it to the door frame and the rib...
And this is what it looks like finished. This is a much better way to secure the aft end of the rib.
Next I drilled all the holes in the lexan. Be very careful and take your time! You don't want extra holes in the window!
Here is the door attached to the fuselage. You can't see it in this picture because the lexan is clear, but the aft end and the bottom are trimmed to fit. The front will get trimmed even with the windshield once it is installed.
This is a view from the front so you can see how the door 'bows' out for extra elbow room.
Just another pic from inside...time to start on the other door.