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One long word
of advice:
The manual wants you to cut holes for the gear
doors, make the 3 bid (as I recall) lip and then leave the rest until it is time
to paint.
DO THIS AND YOU WILL BE SORRY!
The process below might seem longer than the one in
the manual, but is guaranteed to save you time and produce a better
result.
1. Cut holes for gear doors and finish them
completely, so they are nice and round. You should have a template, if not use
the std. gear template and enlarge the holes carefully until large enough. You
want at least 3/4" space between wingskin and wheel. Fill edges with micro and
sand the micro at a slightly outward facing angle ( maybe 5 degrees, just a
little ) in preparation for step 4. The edges need to be sanded with 320
and ready for paint. Make a fairly accurate cardboard pattern for later
use.
2. Hot glue a few mixing sticks on the inside of
the wing skin to act as a temporary stop when fitting the doors.
3. Cut gear doors to fit holes with some 1/16"
space all around. Be careful not to remove too much material at the cockpit
close-out rib, where the inner gear door is solid. This is your final line here,
except for the hinge area.
4. Fill edges of gear door with micro and sand.
Sand inside perimeter of gear door until nice and smooth.
5. Apply release tape on inside perimeter of gear
doors. Use perfectly flat tape, eg. box sealant tape. Duct tape will add work
later. You don´t want work later.
6. Install gear door temporarily. Hot glue some
mixing sticks on outsiude of wing skin and install gear door from the inside,
using small dabs of hot glue on protruding ends of mixing
sticks.
4. Make the 3-bid (as I recall it, consult manual)
lip all way around (not at close-out rib, of course).
5. Remove gear door.
6. Admire smooth lip!
7. Trim and sand lip, 320 grit should be good.
Remember to remove lip at outbd. end, so door can open when hinge is
installed!
8. Apply release tape on lip and edge of gear door
hole. Trim release tape flush with outside of wingskin.
9. Install gear door again using a few very small
dabs of hotglue. You will probably have to heat and twist the door somewhat to
achieve a good fit.
10. First force relatively thin micro in between
door and cut-out. Add more mocroballoons to the mix and fill outside wingskin.
You will probably need a LOT of micro here in order to achieve an
aerodynamically good surface.
11. Sand outside wing skin, fill again as
necessary, sand, fill, sand fill, sand until surface is good
12. Install outboard door hinge. Do not install the
spring between the hinge pins at this time.
13. After cure, pull back hinge pins.
14. Trace outline of gear door using cardboard
pattern made earlier. Cut door free using heatgun and knife. Pry gear door out,
still using the heat gun, remove release tape and sand edges slightly, just
so it opens freely.
15. Install outbd. hinge pins again and sand a nice
and even 1/16" (or slightly more) gap all way around.
16. Cut gear door in two.
17. Fill edges with micro.
18. Make nice gap.
19. Make & trim lip.
20. Think ahead. Always.
Tim Jorgensen
360 Gamma (MKIIOBFB) 90%
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