Lower door skins
I used my template to cutout the lower door skins, then added the door latch template to trace around it and cut it out too. I got a pretty good fit for the latch. However the skin doesn’t lay flat against the whole section and this was always a strong possibility due to the compound curves in the door. I’ve now cut the skin vertically, and the front piece now fits very well. I’m sure the back piece will too, and I plan to join them with rivets, Rather than create a doubler to join, I might recut a new rear skin and simply over-lap and rivet them. But let’s see if it’s going to fit well first. I’m also unsure at this point how the actual “skin” window frame will work out. Plan B is to use a heavier grade aluminium- I may purchase some non-aviation grade skins from the local supplier as it’s a lot cheaper and it’s a non-structural part.