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.

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Comment by Joseph F. Truncale on June 12, 2011 at 1:45pm

Hi Don,

Installed my first door window today. I took your advice one step further and drilled most of the holes with the door on the plane.  I drilled the top hinge holes off the plane since these could never vary.  Then I hung the door and used my "sheet metal hole finder thing" to locate the holes under the lexan and drilled them.  Thanks again for your advice.

Best,

Joe.

Comment by Don Herbel on May 8, 2011 at 8:01am
Thanks, Joe.  I've been following your posts.  The project looks great.  Good Luck
Comment by Joseph F. Truncale on May 7, 2011 at 6:49pm

Thanks for sharing the tip, Don.   I'll be building my doors this year.

Best,

Joe

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