Message-ID: <c=US%a=_%p=CADWELL%l=DEWEY-000811165430Z-4128@dewey.cadwell.com>
From: Carl Cadwell <CarlC@cadwell.com>
To: "'lancair.list@olsusa.com'" <lancair.list@olsusa.com>
Subject: IVP Fast build door installation
Date: Fri, 11 Aug 2000 09:54:30 -0700
Reply-To: lancair.list@olsusa.com
Mime-Version: 1.0

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It took 2 days to prep, fit, adjust and install the fast build door. 
 We made small adjustments to the chain operating the lower latches 
and the exterior handle.  We moved the stud/ball holding the upper end 
of the strut about 1" up and out filling the hole with epoxy/flox and 
2 bid carbon on both sides of the frame.

Installation variances from the manual following discussions with Mark 
at Lancair:
1.	We bolted the top of the fuselage in position.  This allows us to 
 remove the top with the door installed and install the overhead 
console without working overhead.
2.	After fitting the door frame to the opening, the frame needed to be 
aligned to flush out with the fuselage.
3.	Holes were drilled about every 6" around the door frame to hold the 
door in place.  1.5" #8 machine screws and nuts with fender washers on 
the inside and outside were used in lieu of clecos.  This allowed 
positive adjustment of the door frame to flush it to the fuselage
4.	Where the frame needed to be spaced out (held in) from the 
fuselage, 1"x1" phenolic blocks were cut and thinned to the 
appropriate thickness.  8 of these were required.
5.	The door and frame were placed in dry and adjustments were 
verified.  The door and frame were removed and readied to bond to the 
upper fuselage.
6.	The door and frame were attached using 1 2/3 cans of hysol mixed 
with flox.  This allowed enough working time.  The phenolic spacers 
were wetted with hysol and incorporated into the hysol/flox.
7.	The frame was adjusted utilizing the machine screws with fender 
washers to flush it with the fuselage.
8.	It took 11/4 hours to mix, place and adjust the frame.

All looks great.  2 days vs. 2 months is 2 months closer to flying.

Carl Cadwell


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LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
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Please send your photos and drawings to marvkaye@olsusa.com.
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