Preparing the door mechanisms

I started getting the Aerosport handle and the PlaneAround center latch, by cutting the racks in half, then test-fitting all the parts together:

Door lock racks cut in half

Door lock mechanism on the workbench

Door lock mechanism mounted into the door

From the position above, I trimmed the forward and aft pushrods leaving only a couple inches sticking out in the "closed" position, then safety-wired the parts together:

Door lock pushrods and racks safetied together

We then attached the reinforcement blocks around the center latch position:

Center latch reinforcement blocks glued in place

As the last thing before joining the door shells, I decided to add the iflyrv10 door pull strap, so I made doublers for those. The included mounting hardware is kind of useless - they're very long 1/4" screws and nuts, which I wouldn't want inside the door). so I instead used nutplates for #10 screws (the AN520 series has the same head size as the socket screws they included). I attached them (using the same method as for the gas strut attach doublers) to the top-center of the aft part of the door, which will allow us to easily pull the door closed from the ground (without climbing on the wing just for that):

iflyrv10 door pull attachment block and backing doublers

Door pull doubler match-drilled to the door shell and ready to rivet

Door pull block in place over the door pull doubler

Door pull doublers with primer and nutplates

Door pull doubler epoxied in place

Door pull holes, as seen from the inside

Next, there'll be some more sanding to do (e.g. around the reinforcement blocks), and then we'll join the door shells.

Time lapse:

Total cabin door rivets: 32
Total cabin door time: 48.2h

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