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I did a close inspection of our new door, s/n 101, and found the reason the
aft set of latches wern't working: the chain had not been connected.  I
hooked it up and found the bottom latch in the aft row won't latch.  It is
positioned incorrectly and will not center itself.  I removed the base from
the frame and noted that it is half a hole off on the four screw holes which
fasten it to the frame.  Looks like I need to flox the holes and redrill
them.  I'll talk to Mark first to see if there is a better way to gain latch
alignment.  The two forward latches barely engage as they are also out of
alignment but the bevel on the latch "dog" will guide them in.  Maybe I can
re-align those two by loosening things and doing some pushing and shoving
while tightening the fasteners.  The spacer wedges seem to have little
effect, in or out.
The loose screw, indeed, goes to a latch cover, the rivnut is not stripped.
There is a 3/8" scratch, as noted, on the inside of the window which will
take some work to polish out.  The electrical tape around the window
perimeter is covered with Hysol and/or resin and will also be hard to clean
up now that it has hardened.
The door, as it is, will save me much build time.  I guess I'm a
perfectionist and, as an inspector, I'm very picky.  Still, one would expect
a first article to be nearly perfect and not shipped looking as this one
does complete with pieces of masking tape explaining the errors made in
construction and corroded hardware.  But it doesn't need a conformity
inspection or FAA form 8130-3 either.
Well, we're off to see "Space Cowboys".  Enough airplane for one day.
Walter Dodson




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Please send your photos and drawings to marvkaye@olsusa.com.
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