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Paul McAlisters Door pushrod fork.
This is Paul...... Click thumb for more Description
Date: 03/28/2008
Views: 240
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Started fitting port door.
Started fitting port...... Click thumb for more Description
Date: 06/26/2009
Views: 93
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Richie removing gelcoat from door rebate.
Friend Richie removing...... Click thumb for more Description
Date: 06/28/2009
Views: 95
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Allow 3mm glass to recess a little further.
Door and front...... Click thumb for more Description
Date: 06/26/2009
Views: 86
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Art removed gelcoat from windscreen rebate.
Wayne's dad: Art...... Click thumb for more Description
Date: 06/26/2009
Views: 87
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Found many voids and bad areas of layups on doors.
Found many voids and...... Click thumb for more Description
Date: 08/24/2009
Views: 50
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Tiny aberration in gelcoat turns huge.
There was a tiny...... Click thumb for more Description
Date: 08/24/2009
Views: 53
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X-acto saw and then packed in Redux.
Some edge areas...... Click thumb for more Description
Date: 08/24/2009
Views: 52
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This void was pretty big.
This void was pretty...... Click thumb for more Description
Date: 08/24/2009
Views: 56
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Composite rivets 1.
Composite rivets...... Click thumb for more Description
Date: 08/29/2009
Views: 54
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Composite rivets 2.
Composite rivets...... Click thumb for more Description
Date: 08/29/2009
Views: 57
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Composite rivets 3.
Composite rivets...... Click thumb for more Description
Date: 09/08/2009
Views: 40
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Laid up 1 BID of carbon fiber
Laid up 1 BID of...... Click thumb for more Description
Date: 08/31/2009
Views: 61
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Extended carbon fiber onto hinge lug.
Extended carbon fiber ...... Click thumb for more Description
Date: 08/31/2009
Views: 52
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After layup was complete, peel plied.
Laid up both starboard...... Click thumb for more Description
Date: 09/01/2009
Views: 56
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Filled with Aeropoxy light starboard.
Cleaned up carbon...... Click thumb for more Description
Date: 09/03/2009
Views: 52
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Filled with Aeropoxy light port.
Cleaned up carbon...... Click thumb for more Description
Date: 09/03/2009
Views: 41
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Filled glassed over hole on port door.
Filled glassed over...... Click thumb for more Description
Date: 09/03/2009
Views: 47
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Sanded starboard door.
Sanded Aeropoxy light ...... Click thumb for more Description
Date: 09/09/2009
Views: 38
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Sanded port door.
Sanded Aeropoxy light ...... Click thumb for more Description
Date: 09/09/2009
Views: 37
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Filled and sanded shoot bolt bushing.
Probably getting a bit...... Click thumb for more Description
Date: 09/09/2009
Views: 39
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Port door lower aft repair and fill complete.
Port door lower aft...... Click thumb for more Description
Date: 10/07/2009
Views: 26
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Tried to cut door hinges in Makita chop saw.
Tried to cut door...... Click thumb for more Description
Date: 10/08/2009
Views: 30
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Alan's finger was part of the clamp.
Alan's finger was part...... Click thumb for more Description
Date: 10/17/2009
Views: 22
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Good old hack saw was used to do the deed, indeed.
Good old hack saw was ...... Click thumb for more Description
Date: 10/08/2009
Views: 29
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Each hinge is slightly different in size, and pins are as large as they can be.
Each hinge is slightly...... Click thumb for more Description
Date: 10/08/2009
Views: 30
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Boy, under an oz each side.
Boy, under an oz each ...... Click thumb for more Description
Date: 10/08/2009
Views: 31
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Planning how to best hang door.
Planning how to best...... Click thumb for more Description
Date: 10/08/2009
Views: 32
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Non drying Prussian blue close at hand.
After study, I really ...... Click thumb for more Description
Date: 10/08/2009
Views: 31
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Dab tip port door aft.
Dab tip port door...... Click thumb for more Description
Date: 10/08/2009
Views: 27
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No problem dotting fuse, but you must careful study tip of shoot bolt.
No problem dotting...... Click thumb for more Description
Date: 10/08/2009
Views: 31
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Took a night to make 2 holes.
Took a night to make 2...... Click thumb for more Description
Date: 10/09/2009
Views: 32
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Port aft going 1.
Port aft going...... Click thumb for more Description
Date: 10/09/2009
Views: 32
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Port aft going 2.
Port aft going...... Click thumb for more Description
Date: 10/09/2009
Views: 30
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Port aft going 3.
Port aft going...... Click thumb for more Description
Date: 10/09/2009
Views: 34
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Port aft going 4.
Port aft going...... Click thumb for more Description
Date: 10/09/2009
Views: 31
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Port aft gone!
Port aft gone!
Y9-10-09... Click thumb for more Description
Date: 10/09/2009
Views: 31
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Port front enlarging 1/8" hole.
Port front enlarging...... Click thumb for more Description
Date: 10/08/2009
Views: 32
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Needs some steering.
Needs some...... Click thumb for more Description
Date: 10/08/2009
Views: 32
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Here just a slight amount of steering is needed.
When you get this...... Click thumb for more Description
Date: 10/09/2009
Views: 32
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Starboard front going 1.
Starboard front going ...... Click thumb for more Description
Date: 10/09/2009
Views: 35
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Starboard front going 2.
Starboard front going ...... Click thumb for more Description
Date: 10/09/2009
Views: 38
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Starboard front gone!
Starboard front...... Click thumb for more Description
Date: 10/09/2009
Views: 33
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Port full opened.
Port full...... Click thumb for more Description
Date: 10/09/2009
Views: 30
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Port half opened.
Port half...... Click thumb for more Description
Date: 10/09/2009
Views: 35
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Port not opened at all!
Port not opened at...... Click thumb for more Description
Date: 10/09/2009
Views: 31
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Just plain slight imperfection on door rebate edge.
Man, just admiring...... Click thumb for more Description
Date: 10/09/2009
Views: 35
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Careful contemplation while devising plan how to best locate hinges on port door.
Careful contemplation ...... Click thumb for more Description
Date: 10/10/2009
Views: 35
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Locating where hinge pins will go.
First off double...... Click thumb for more Description
Date: 10/10/2009
Views: 32
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Transfer mark from top to bottom of door tangs.
Once I had markings on...... Click thumb for more Description
Date: 10/10/2009
Views: 31
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Used the 1/4-20 bondable stud in drill press to proper position door.
Bonded hinges with JB ...... Click thumb for more Description
Date: 10/12/2009
Views: 31
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Holes are only 1/16" to allow proper countersinking of top tang.
Holes are only 1/16"...... Click thumb for more Description
Date: 10/12/2009
Views: 26
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Port door front hinge in perfect position.
Port door front hinge ...... Click thumb for more Description
Date: 10/10/2009
Views: 26
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Port aft hinge in position to make spacer.
Port aft hinge in...... Click thumb for more Description
Date: 10/10/2009
Views: 28
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Used these tools to measure gap.
Used these tools to...... Click thumb for more Description
Date: 10/14/2009
Views: 25
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Port front spacer complete and held in place with double sticky tape.
Port front spacer...... Click thumb for more Description
Date: 10/12/2009
Views: 22
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Port front spacer is thicker than port rear spacer.
Port front spacer is...... Click thumb for more Description
Date: 10/12/2009
Views: 26
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Port aft spacer is thinner than front.
Port aft spacer is...... Click thumb for more Description
Date: 10/12/2009
Views: 27
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Bonding port front spacer to fuse with JB KWIK weld.
Bonding port front...... Click thumb for more Description
Date: 10/13/2009
Views: 20
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Bonding port aft spacer to fuse with JB KWIK weld.
Bonding port aft...... Click thumb for more Description
Date: 10/13/2009
Views: 18
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Once door is removed will countersink top half of hinge.
Once door is removed...... Click thumb for more Description
Date: 10/13/2009
Views: 19
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Trimmed tang overhang inboard of the inboard edge of hinge leaving thickness of tang plus 10%.
Trimmed tang overhang ...... Click thumb for more Description
Date: 10/13/2009
Views: 22
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Port front spacer perfectly bonded in position.
Port front spacer...... Click thumb for more Description
Date: 10/15/2009
Views: 18
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Port aft spacer perfectly bonded.
Port aft spacer...... Click thumb for more Description
Date: 10/15/2009
Views: 21
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View of port aft hinge from bottom up.
View of port aft hinge...... Click thumb for more Description
Date: 10/16/2009
Views: 22
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Used a 1/8" piloted 100 degree counterbore to counterbore hinges.
Used a 1/8" piloted...... Click thumb for more Description
Date: 10/14/2009
Views: 24
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Nice fit.
Nice fit. Filed a nice...... Click thumb for more Description
Date: 10/14/2009
Views: 24
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Token counterbore.
After the tang had a...... Click thumb for more Description
Date: 10/15/2009
Views: 18
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Mounted top port front hinge.
Mounted top port front...... Click thumb for more Description
Date: 10/15/2009
Views: 19
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Port aft hinge mounted as well.
Port aft hinge mounted...... Click thumb for more Description
Date: 10/15/2009
Views: 20
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Supplied nuts are too thick for the thin side of the tang 1.
Supplied nuts are too ...... Click thumb for more Description
Date: 10/14/2009
Views: 20
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Supplied nuts are too thick for the thin side of the tang 2.
Much more better to...... Click thumb for more Description
Date: 10/14/2009
Views: 17
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4 nuts sanded down to .125"
4 nuts sanded down to ...... Click thumb for more Description
Date: 10/14/2009
Views: 23
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This is the gap at high point on port door.
This is the gap at...... Click thumb for more Description
Date: 10/15/2009
Views: 18
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Gave the top of door a bit more clearance to fuse.
Gave the top of door a...... Click thumb for more Description
Date: 10/17/2009
Views: 20
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Port front tang perfect length.
Port front tang...... Click thumb for more Description
Date: 10/16/2009
Views: 19
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Port front tang rebate prepared for closing gap a bit.
Port front tang rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 18
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Port front tang rebate, going to use thin G-10 to cover gap.
Port front tang...... Click thumb for more Description
Date: 10/16/2009
Views: 16
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Port front tang gap cover shaped.
Port front tang gap...... Click thumb for more Description
Date: 10/16/2009
Views: 24
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Port front gap cover floxed in place.
Port front gap cover...... Click thumb for more Description
Date: 10/17/2009
Views: 20
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Port front hinge area complete.
Port front hinge area ...... Click thumb for more Description
Date: 10/17/2009
Views: 16
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Port front hinge gap cover just about ready to touch door when it is opened.
Port front hinge gap...... Click thumb for more Description
Date: 10/16/2009
Views: 20
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Port aft tang/rebate 1.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 20
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Port aft tang/rebate 2.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 16
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Port aft tang/rebate 3.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 18
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Port aft tang/rebate 4.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 20
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Port aft tang/rebate 5.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/17/2009
Views: 23
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Port aft tang/rebate 6.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/17/2009
Views: 19
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Port aft tang/rebate 7.
Port aft tang/rebate...... Click thumb for more Description
Date: 10/16/2009
Views: 24
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Repair screwup on starboard door 1.
Repair screwup on...... Click thumb for more Description
Date: 10/20/2009
Views: 28
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Repair screwup on starboard door 2.
Repair screwup on...... Click thumb for more Description
Date: 10/20/2009
Views: 24
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Repair screwup on starboard door 3.
Repair screwup on...... Click thumb for more Description
Date: 10/20/2009
Views: 24
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Top of starboard door fits pretty well at this point, now to fit the bottom.
Top of starboard door ...... Click thumb for more Description
Date: 10/20/2009
Views: 21
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Fold over bout 1/2"
Fold over bout...... Click thumb for more Description
Date: 10/20/2009
Views: 23
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Starboard door fit, there are 2 clamps on hinge tangs holding door in place.
Starboard door fit,...... Click thumb for more Description
Date: 10/20/2009
Views: 20
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Took a little less than 2 hours to fit bottom of starboard door including cleaning up sanding dust.
Took a little less...... Click thumb for more Description
Date: 10/20/2009
Views: 27
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Tip of starboard door handle hits fuse 1.
Tip of starboard door ...... Click thumb for more Description
Date: 11/01/2009
Views: 8
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Tip of starboard door handle hits fuse 2.
Tip of starboard door ...... Click thumb for more Description
Date: 10/22/2009
Views: 24
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Tip of starboard door handle hits fuse 3.
Tip of starboard door ...... Click thumb for more Description
Date: 10/29/2009
Views: 10
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Going to taper sand away about half thickness of aluminium at tip 1.
Going to taper sand...... Click thumb for more Description
Date: 10/22/2009
Views: 24
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