This section is mostly straight forward - cleco everything together and final-drill:
|Main door parts clecoed together and final-drilled|
|Marking the hinge holes for the door side|
|Marked hinge for drilling|
I also used the common deviation from plans that involves cutting half the hinge eyes so that pins can be inserted from the center, allowing the whole hinge to be closer to flush with the skins:
|Door hinge with 3 half eyes removed for pin insertion|
|Making the door hinge almost flush with the skin|
Finally, the recommended method to drill the other half of the hinge to the fuselage involves modifying clecos so they fit inbetween the halves:
|Specially modified clecos for the door hinge|
then centering the door and match-drilling from the inside:
|Door centered in place and held by tape|
|Accidental double hole when drilling the fuselage side of the door hinge :/|
|Match-drilled and countersunk door hinge|
The next steps are just deburring, primer and riveting.
I was also considering adding a baggage door sensor (microswitch or similar), but given how hard that'll be, it's probably not worth it.
Total baggage door time: 5.5h