Section 45 Cabin Doors and
Transparencies
Pages 45-07 thru 45-14
Page 45-07
Step 1: Place the C-1002-L Door on the fuselage and hold it in place with duct tape.
Working from inside the cabin, match-drill #12 one of the outboard holes in each of the WD-1019 Door Hinges. Temporarily install a screw/washer/nut through the door hinge and C-1002-L Door as shown in Figure 1. Match-Drill #12 the remaining outboard hole in each door hinge and install screw/washer/nut.
Step 3: Un-tape the C-1002-L Door, Swing it open and match -drill #12 the remaining 2 holes in each WD-1019 Door Hinge as shown in Figure 2.
Machine countersink the outside surface of the door at the four open holes. Install screw/washer/nuts in countersunk holes, Remove screw/washer/nuts from the holes not yet counter sunk and counter sink the holes. Install screw/washer/nuts in the holes.
Close the door and see if it distorts. If the door wants to ride too low relative to the cabin cover shim between the inside surface of the door and WD-1019 Door Hinges.
Step 4: Repeat Steps 1 through 3 for the C-1002-R Door.
Step 5: Remove the C-1002-L and C-1002-R Doors from the WD-1019-L/R Door Hinges.
Page 45-08
Step 1: Initial trim the perimeter of the C-1003-L and C-1003-R Front Windows to the line marked on the windows. See Section 5U for guidelines on handling and trimming Plexiglas.
Step 2: Test fit the C-1003-L Front Window to the C-1002-L Door as shown in Figures 1 and 2. Mark any areas of the front window outside perimeter which require further trimming in order to fit to the recess in the door. Final-Trim the perimeter of the front window as required to allow it to fit into the recess in the door. Small amounts of material are best removed with 80 to 100 grit sandpaper on a long (approximately 12 inches) sanding block.
Use the same process to fit the C-1003-R Front Window to the C-1002-R Door.
Step 3: Smooth the edges of the C-1003-L and C-1003-R Front Windows with 220 grit sandpaper to remove any scratches that could cause a crack to begin.
Step 4: Mask the inner and outer surfaces of the C-1003-L/R Front Windows except for a 3/4 inch wide strip around the perimeter where they overlap the C-1002-L/R Door window recesses. Scuff the mating surface of the windows and door recesses with 220 grit sandpaper.
Step 5: Re-fit the C-1003-L/R Front Windows to the recesses in the C-1002-L/R Doors. The thickness of the Plexiglas will vary around the perimeter of each window. Shims can be used between the windows and the door recess where required to raise the outer surface of the window to more closely match the outer surface of the door. See Figure 2.
AN960-6 washers make very convenient shims.
The distance between adjacent shims need not be less than approximately 4 inches.
Use epoxy to glue the shims to the surface of the door recesses.
NOTE: Van's Aircraft recommends the use of Weld-On 10 to attach all transparencies to the C-1001 Cabin Cover. Weld-On 10 is available from Van's Aircraft in 4 oz. kits. One 4 oz kit is required for each transparency.
Step 6: Place the C-1002-L Door on a table or other flat surface with the window recess facing up.
Apply a thin layer of Weld-On 10 to the window recess portion of the door and remove any excess. Immediately place the C-1003-L Front Window in the window recess and seat it down onto the window recess and/or shims. Remove any excess glue that has squeezed-out and use a finger or popsicle stick to create a fillet of glue between the inside edge of the door recess and the inside surface of the front window. (Cured Weld-On 10 is very hard; drips or sags will be difficult to remove later.) Use small weights or duct taped to hold the front window in place while the Weld-On 10 Cures.
Repeat for the opposite side door and front window.
Page 45-09
Step 1: Use a 1/2 inch diameter drill to make a center mark at the bottom of the hole in the C-656 Canopy Handle.
Using a center mark to keep the bit that is called-out in Figure 1 concentric to the existing hole, drill through the canopy handle as shown in Figure 1.
Drill a pilot hole located as shown in Figure 1.
Round the corners of the canopy handle as shown in Figure 1.
Step 2: Insert the WD-1022 Door Handle Assembly all the way into the C-656 Canopy Handle as shown in Figure 2.
Check that the surfaces of the door handle assembly and canopy are aligned as shown in Figure 2., then match-drill #29 through the door handle assembly using the hole in the canopy handle as a drill guide. Drill 1 inch deep as measured from the outside surface of the canopy handle.
Step 3: Remove the C-656 Canopy Handle from the WD-1022 Door Handle Assembly.
Final-Drill #19 the #29 holes through the door handle assembly then deburr the holes.
Step 4: Final-Drill #19 the #29 holes through the near side only of the canopy handle.
Tap the far side #29 hole using an 8-32 tap.
Test fit the AN-509-8 screw into the canopy handle as shown in Figure 2. Drill and tap deeper if/as required for the screw to fully thread into the canopy handle.
Page 45-10
Step 1: Temporarily assemble the C-1066A Handle Plate, C-1006B & C-1006C Handle Pivots, C-1006D Handle Face Plate, C-1014 Handle Spur Gear, and the WD-1022 Door Handle Assembly as shown in Figure 1. Align the edges of the handle plate, handle pivots, and handle face [late and match drill #10 two places as shown in Figure 1. Remove the C-1006C Handle Pivot and the handle spur gear. Match-Drill #40 through the C-1006D Handle Face Plate, C-1006A Handle Plate, and C-1006B Handle Pivot four [places as shown in Figure 1.
Disassemble all parts.
Final-Drill #10 the #40 holes in the C-1006B Handle Pivot.
Final-Drill 9/32" the #10 holes in the C-1006A Handle Plate.
Deburr drilled holes in all parts.
Step 2: Rivet the C-1006A Handle Plate and C-1006D Handle Face Plate to each other and install nutplates as shown in Figure 2.
Step 3: Final-Drill and round the corners of the narrow end of each C-1008 Handle Lever as shown in Figure 3. Smooth all edges of the handle levers.
Step 4: Install a nutplate on the WD-1022 Door Handle Assembly as shown in Figure 4. Install a nutplate on the remaining door handle assembly on the side opposite that shown in Figure 4.
Page 45-11
Step 1: Cut each C-RACK 10" Handle rack into two pieces as shown in Figure 1.
Install a blind rivet into one end of each handle rack.
Step 2: Insert the C-1014 Handle Spur Gear into the C-1006C Handle Pivot. Position the handle pivot/pivot gear on the latch pocket of the C-102-L Door as shown in Figure 2. Center the handle pivot in the latch pocket both vertically and fore/aft as shown in Figure 3. With the handle pivot held in position, match-drill a 1/2 inch hole through the door using the handle spur gear as a drill guide.
Step 3; Insert the WD-1022 Door Handle Assembly through the C-1014 Handle Spur Gear and through the hole just drilled through the C-1002-L Door. See Figure 2. This will hold the C-1006C Handle Pivot centered on the hole in the door, Recheck that the edges of the handle pivot are aligned with the edges of the latch pocket and match-drill #12 through the door using the holes in the handle pivot as a drill guides. See Figure 3.
Step 4: Repeat Steps 2 and 3 for the C-1002-R Door
Page 45-12
Picture depicts the aft block being drilled, forward block is done the same way.
Step 1: Position the C-1009 Door Forward Pin Block in the pocket in the C-1002-L Door as shown in Figure 1 and 3. Round the upper, aft, and lower outboard edges as required for the door forward pin block to neat tightly against the door. The door forward pin must not protrude beyond the forward "wall" of the door.
With the door pin block in place, match-drill #121 through the door using the holes in the door fwd pin block as drill guides.
Remove the door fwd pin block and mark "left" or "right" as appropriate.
Step 2: Aft block is done the same way.
Step 3: Machine countersink the outer surfaces of the C-1002-L Door at all #12 holes (six places per door) to fit the head of an AN509-10 screw. It is better to under-countersink by .010 to .015 depth at this point in construction.
Step 4: Attach the C-1009 Door Fwd Pin Block and C-1017 Door Aft Pin Block to the C-1002-L Door as shown in Figure 3.
Match drill 7/16 into the walls of the door using the holes in the pin bocks as drill guides. Remove the fwd and aft pin blocks. Enlarge the 7/16 holes to 15/32 or 1/2 inch.
Re-install the forward and aft pin blocks
Step 5: Repeat Steps 1 thru 4 for the right side door.
Page 45-13
Step 1: Secure the VA-197 Spring and C-1007 Handle Slide to the WD-1022 Door Handle Assembly with a roll pin as shown in Figure 1.
Step 2: Secure the C-1008 Handle Lever to the WD-1022 Door Handle Assembly with a screw as shown in Figure 2. When the Handle lever is secured in place, the narrow end must engage the opening in the C-1007 Handle Slide as shown in Page 45-10, Figure 3.
Slide the C-1006D Handle Face Plate/C1006A Handle Plate Assembly and the C-1006B Handle Pivot onto the door handle assembly as shown in Figure 2.
Attach the C-1014 Handle Gear Spur to the door handle assembly using a roll pin as shown in Figure 2. The ends of the roll pin must be flush with the outside diameter of the handle spur gear.
Note: For initial assembly of the Latch Mechanism shown in Figure 3 temporarily install the Rack Trimmings (see page 45-11, Figure 1) rather than the handle racks.
Step 3: Place two Handle Racks of the C-1014 Handle Spur Gear as shown in Figure 3.
Slide the C-1006 C Handle Pivot over the handle spur gear and handle racks as shown in Figure 3.
Step 4: Attach the Latch Mechanism to the C-1002-L Door as shown in Figure 4.
Operate the latch mechanism so as to cause the Rack Trimmings to extend fore and aft from the latch mechanism and lightly contact the walls of the latch pocket.
Mark the walls of the latch pocket around the ends of the rack trimmings and remove the latch mechanism from the door.
Drill 1/2"diameter (minimum) holes in the walls of the latch pocket. Temporarily re-attach the latch mechanism to the door and operate the latch mechanis. Enlarge the holes in the walls of the latch pocket if/as required to allow the ends of the rack trimmimgs to pass through with clearences of 1/16 to 1/18.
