Doors, Windshield pillars, Door sills

Doors

I spent most of today working on the front doors. When I made them quite a few months ago, they fit almost too perfectly. I plan to glue a rubber channel around the outside of the doorskin as a protector against hitting your head on it when the door is open, and this made the door too tight for the mechanism to work effectively.

So today I disassembled the whole mechanism and widened all the holes, and adjusted the locking bars. After several hours the result was much smoother latching, while still being robust. And I did a trial with the rubber channel strip, and it fits well.

Here I’ve installed a split pin to limit the movement when the door is opened :

I did a trial fitting with the rubber channel :

Windshield pillars

I used silicon to seal the Kydex along the door pillars. This is mainly so the holes line up easily when I screw the windshield through the Kydex.

Door sills

I screwed the right side door sill into place. This also locates the lower aluminium skin properly.