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Dear David,
 
I'm still a year and a half away from flying roughly, but didn't like the
nose gear door either.  I might be out on a limb with my substitution, but
I'll let you know after the fact.   I'm using graphite materials to make the door from - have built the doors
themselves and, of course, have plenty of carbon hinge on hand.  the top
hat stiffener will also be made of graphite (unidirectional).  Hysol will
be the attaching material and we'll see how it goes. I certainly don't
recommend it as a fix in your situation, but thought you'd like to hear
another idea.  It's possible that  mine will break off as some aluminum
ones have, but I doubt that the parts will separate as did your rivets.
 
I do know that Hysol is somewhat flexible in its cured state and it bonds
like crazy to roughened aluminum that has been cleaned up with Methylene
Chloride.  That might be a solution you could live with a la the suggestion
to bond with RTV.
 
Regards,
John Barrett
Barrett/Garrett Enterprises, Inc.
 
PS Are you sure it's not the mercury in your fillings?  Sorry - couldn't
resist.  Best of luck with your door.

LML homepage:   http://www.olsusa.com/Users/Mkaye/maillist.html