I epoxied the magnets inside the door latch pins (and later carefully cleaned up the threads):
Door latch pins with magnets epoxied inside
I had to try a few different sensor positions to get the right sensitivity - in the end, attaching to the top screw worked well:
Attempted reed sensor position that didn't work
Reed sensor position that worked properly
Testing the door sensor
I then started the work to close up the hinge pockets, so that the McMaster seal can seal that part of the door. I made 4-layer fiber "plaques", trimmed them to fit just slightly inside the hinge pockets, then attached them with two more layers underneath (grabbing the sides of the pockets), and two layers on top (to make a smooth transition, and also to follow the cranial cavity curve):
Laying up a flat plaque for closing the door hinge pockets
Sanded hinge pockets for attaching the covers
Hinge pocket cover plaques marked up for trimming
Hinge pocket cover plaque held in place
Hinge pocket cover plaque held in place
I used some 2x4s (on top of peel ply) to keep the layup on the same plane as the original door surface:
2x4 block "press" to keep hinge pocket covers flat with door surface
Hinge pocket cover fiber layup inside the pockets
Hinge cover layup in place
After a lot of sanding and filling to make it smooth again, I applied a coat of primer, and this is now ready to fit back:
Hinge pocket covers after sanding
Filling holes in the hinge pocket covers
Hinge pocket covers with primer applied
With this done, I can finish fitting the McMaster seal, position the gas strut bracket and drill the door to attach it.
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