52-10 Door Assembly (continued)
D. Replacement
CAUTION
Use proper respiratory protection when handling fiberglass.
CAUTION
Protect door windows and paint from scratches or scuff marks
when door maintenance is performed on workbench.
1. Refer to Figure 52-1. As required, lay masking tape on surfaces of door frame,
new door hinges, and new door, to mark with soft pencil.
2. Press new door forward and top edge weather seals against door frame recess (rain
gutter interferes with top edge until trimmed).
3. Using soft pencil, trace door forward edge onto masked frame, then transfer
approximate edge distance to door. From inside cabin, estimate approximate
material to be removed from door top edge, then transfer approximate edge distance
to door. Remove door.
4. Using 60-grit grinder, trim forward and top door edges. Perform steps 1 thru 3
until weather seals sit approximately even against door frame recess.
5. Using soft pencil and a straight edge, draw cross hairs through (centers of) door
upper hinge assembly pre-drilled holes. Hold fitted door against frame, insert new
(door-mounted) hinge assembly in frame-mounted hinge assembly, and transfer
cross hairs onto hinge. Remove hinge and door.
6. Drill two 0.170-inch diameter holes at cross hair intersections in hinge assembly
and deburr. Remove tape, clean up debris, and prepare hinge assembly and door
clamping surfaces using approved solvents per § 20-70.
7. Install upper hinge assembly on door and special torque screws per § 20-33.
8. Repeat steps 5 thru 7 for lower door-mounted hinge assembly.
9. Install door. Using 60-grit grinder, trim edges as required for final fitting. Verify
doors open and close smoothly and latch correctly. Remove door and bevel edges
using 60-grit sandpaper.
10. Prepare surfaces with solvent and touch-up door using approved materials per §
20-70. Install new door per § 52-10.
JUL 2020 Chapter 52 Doors and Windows Page 52.3
To Next Page
