52-10 Door Assembly (continued)
C. 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 Section 20-70.
7. Install upper hinge assembly on door and special torque screws per Section 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 Section
20-70. Install new door per Section 52-10.
25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows Page 52.3
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