There are six dimples molded into the tool side of each cabin door shell, one near the lower forward edge, one near the lower door aft edge, and one in the window flange near each of the four corners of the window. Drill #40 hole through the cabin door outer shell at the center of each of the six dimples. These are "index holes' used to locate the door shells to each other and the fuselage.

Draw two lines on the window flange of each door outer shell, one 3/4 inch offset from the window joggle and one 1/14" offset from the window joggle.

On the 1 1/4" line make a mark approximately every 1 1/2 inch around the window perimeter. Drill a #40 hole.

Step 2: Trim the outside perimeter and window flange of the C-1002B-L and -R Cabin Door Inner Shells as shown in Figure 2.

The tool side of each cabin door inner shell has molded dimples that correspond to the dimples molded into the C-1002A-L and R Cabin Door Outer Shells. Drill a #40 hole through the cabin inner shell at the center of each of the six dimples.

Step 3: Sand the bag side surface of the C-1002A-L and -R Cabin Outer Shells in the areas that will mate to the C-10002B-L and-R Cabin Door Inner Shells. The mating areas are shown shaded in Figure 1.

Step 4: Sand the bag side surface of the C-1002B-L and R Cabin Door Inner Shells in the areas that will mate to the C-1002A-Land -R Cabin Door Outer Shells.

Page 45-03

Step 1: here are several rivet holes in the fuselage that were deliberately left open to facilitate gluing the C-1002A Door Our Outer Shells to the C-1002 Door Inner Shells. See Page 29-17, Figures 1 &2, and page 29-18, Figure 1. At each of the open holes draw reference lines on the fuselage side so that the hole centers can be located when covered. See Figure 1. If you have a hole finder you can skip this step

Step 2: Cleco the C-1002A-L Door Outer Shell to the C-1002B-L Door Inner Shell using the four #40 holes in the window flange of the door inner shell. See Figure 2.

Step #; Cleco the C-1002A-L Door Outer Shell/C-1002B-l Door Inner Shell to the fuselage using the forward and aft index holes.

Verify that there is a constant 1/16 to 1/8 inch gap between the C-1002B-L Door Inner Shell and the return flange of the C-1001 Cabin Cover. Trim or sand the cabin cover return flange if/as required to achieve the required gap. See Page 45-04, Figure 1," Stage 1: Initial Placement on Fuselage.

Page 45-04

Step 1: `Using the open hole reference lines (or hole finder) drill #40 through the C-1002A-L Door Outer Shell/C-1002B-L Door Inner Shell into the open rivet holes in the fuselage. See Page 45-03. Figure 1. Install a cleco in each hole as it is drilled. If any mismatch occurs, the hole in the door inner/outer shells should be elongated rather than the hole in the fuselage. The Clecos are used to hold the door inner/outer shells tightly to the side of the fuselage.

Duct tape the upper part of the C-1002A_L Door Outer Shell/C-1002B-L Door Inner Shell to the C-1001 Cabin Cover. The duct tape should hold the door inner/outer shells to the upper cabin cover as tightly as possible.

Step 3: Match-Drill #40 the holes in the window flange of the C-1002A-L Door Outer Shell into the window flange of the C-1002B-L Door Inner Shell. Install a cleco in each hole as it is drilled.

Step 4: Remove the C-1002A-L Door Outer Shell/C-1002B-L Door Inner Shell from the fuselage and separate the door outer shell from the door inner shell.

Step 5: Repeat all preceding steps for the right side door

Step 6: Position one of the C-1002C Gas Strut Attach Doublers on the bag side surface of the C-1002B-L Door Inner Shell as shown in Figure 2.

The Gas Strut attach Doubler centers on the width of the aft hinge pocket molded into the door inner shell.

The Shape of the gas strut attach Doubler can be adjusted as required to achieve a good fit to the door inner shell. The fit need not be perfect because the glue used to attach the gas strut attach Doubler to the door inner shell will easily fill any gaps of up to 1/16th inch.

Match-Drill #30 and cleco the gas strut attach Doubler to the door inner shell. Remove the gas strut attach Doubler and deburr the holes.

Repeat this step for the right side door.

Step 7: Mix some epoxy and thicken it with cab-o-sil to the point that it will not pour out of the mixing cup. A total mixture quantity of about 2 fluid ounces will be required.

Use 80 grit sandpaper to roughen the mating surfaces of the C-1002B-L & R Door Inner Shells and C-1002C gas strut attach doublers.

Apply 1/16 inch thick layer of thickened epoxy to each gas strut attach Doubler and cleco each one to the appropriate door inner shell. Use two clecos for each gas strut attach Doubler inserted through the two hole on the part centerline. Install the clecos from the tool side of the door  inner shells. Use hand pressure to seat the gas strut attach doublers to the door inner shells and to squeeze out any excess epoxy which should be removed.

After the epoxy has cured re-drill the holes to #30 and install rivets as shown in Figure 2.

Page 45-05

Step 1: There are three locations on each door where the bag sides of the C-1002A Door Outer Shell and C-1002B Door Inner Shell are locally bonded together. The three locations are as follows: The "cranial cavity" in the upper door shell above the window, the" latch pocket" in the lower door, and the "elbow cavity" in the lower door aft of the latch pocket, and the cranial cavity and elbow cavity the door shell require a "bridge" of structural filler material between the.

The material used for the structural filler is a 3 dimensional weave glass called ParaBeam.

Cut four pieces of ParaBeam (two for each door) to the dimensions shown in Figure 1.

Step 2: :Mask-off the fuselage in anticipation of joining the C-1002A Door Outer Shell and C-1002B Door Inner Shell in place on the fuselage.

NOTE: Steps 3-8 must be done in a single work session. This will require use of an epoxy with a 30 minute (minimum) pot life.

Step 3: Brush a light coat of epoxy of the bag sides of the C-1002A-L Door Outer Shell and C-1002B-L Door Inner Shell at the three places where they are bonded together.

Step 4: Wet-out with epoxy each of the two pieces of parabeam for the left door then place it at the appropriate spot on C-1002B-L Door Inner Shell.

Step 5: Mix some epoxy and thicken it with cab-o-sil to the point that it will not pour out of the mixing cup. A total mixture quantity of about 10 ounces will be required.

Apply a 1/32 to 1/16 inch layer of thickened epoxy to all the mating surfaces around the door outside perimeter and window inside perimeter of the C-1002B-L Door Inner Shell. These areas are shown shaded on Page 45-02, Figure 2.

Step 6: Put one cleco at the lower forward corner and one cleco at the lower aft corner of the C-1002A-l Door Outer Shell.

Allowing contact only along the lower edge, use the two clecos to join the door outer shell to the CC-1002B-L Door Inner Shell. Lay the remainder of the door outer shell in place on the door inner shell and cleco them together at only the upper forward and upper rear corners of the window.

Step 7: Place the C-1002A-L door inner shell/C-1002B-l door out shell subassembly on the fuselage and cleco it to the fuselage at the two index holes.

Insert clecos through the door inner shell/door outer shell and into all the open holes in the fuselage

Insert clecos through all the holes around the perimeter of the window.

Use C-clamps, small weights, duct tape, or whatever works to hold the door inner shell and door outer shell tightly to each other AND to the fuselage while the epoxy cures, Apply hand pressure to push-out any excess thickened epoxy between the parts. Use only light pressure if you use C-clamps or other mechanical clamps so as not o locally distort the door shells. Any irregularities will be permanent after epoxy has cured.

Step 8: After the door is fully cured remove all clecos, clamps, weights, duct tape then remove door from fuselage.

Step 9: Repeat steps 3-8 for other side. The doors will subsequently be referred to as the C-1002-L Door and C-1002-R Door.

Step 10: Trim the window openings in the C-1002-L and R Doors such that a 3/4 inch wide flange remains. This trim line was drawn per Page 45-02, Step 1.

Step 11: Trim the outside perimeter of the C-1002-L and R Doors to within 1/8 inch of the molded scribe line except leave a small tab-out at the front and rear indexing holes. See Page 45-04, Figure 1, "Stage 2: Tri to Fit Opening in Cabin Cover".

Further trimming in the nice weather outside

Left Door glued together hangar ready for Christmas open house and RV builders meeting

Cleco the doors back on to the fuselage. Mark any areas of the door outside perimeter which require further trimming in order to fit to the fuselage. Small amounts of material are best removed with 80 to 100 grit sandpaper on a long (approximately 12 inches) sanding block.

Step 12: Trim the indexing hole tab-outs from the C-1002 Doors. Sand a 45 degree bevel into the outside perimeter of the doors as shown on Page 45-04, Figure 1,"

Stage 3: Remove Index Hole Tab-Outs and Bevel Edges". Trim/sand door as required for it to just fit the opening in the fuselage.

Page 45-06

Step 1: Cut-off the threaded ends of four AN3-21A bolts as shown in Figure 1.

Step 2: Using the cut-off bolts as hinge pins, assemble the WD-1018-L Cabin Hinges to the WD-1019-L Door Hinges and assemble the WD-1018-R Cabin Hinges to the WD-1019-R Door Hinges as shown in Figure 2.

Step 3: Position the WD-1018-L Cabin Hinge/WD-1019-L Door Hinge Subassembly in the forward pocket in the C-1001 Cabin Cover. Position the WD-1018-R/WD-1019-R Door Hinge subassembly in the aft pocket in the cabin cover. See Figure 3.

The WD-1018-L and -R are located on the cabin cover as shown in Figure 3 and 4. Use three .125 thick scrap aluminum spacers to locate each cabin hinge t the "walls" of the hinge pockets.

With the cabin hinges held in location, match-drill #12 through one of inboard holes in each cabin hinge into the cabin cover. Bolt each cabin hinge in place. See Figure 4.

Use a straight edge to draw a reference line on the cabin cover as shown in Figure 4. Use the reference line to align the forward and aft cabin hinges to each other. Pivot the cabin hinges about the bolts if/as required to bring them into alignment and match-drill #12 through the three remaining holes in each cabin hinge and into the cabin cover. Install screws/washers as shown in Figure 3.

Repeat this step for the right door hinges.

Forward to page 45-07