Online Community of Zenith Builders and Flyers
The photo assembly guides depict the door window plastic being installed sitting on the work table. Absolutely put the door frame back into the jig before pilot drilling the window to the frame! Finding this out the hard way: door was twisted and would no longer fit in the cabin opening. I was able to reposition the assembly in the jig and re-drill the pilot holes in the bottom edge and forward and aft door frame tubes and salvage the Lexan plastic. The upper hinge and the door side panel will hide the errant holes and the ones in the tubes are repairable. Taking this lesson to practice on the other door worked great--excellent fit on both doors now.