finally discovered some acceptable Satin Clear. 2-part with a diamond
hard finish, this stuff is as hard to get as it is toxic and
hazardous. Just doing the inside of the doors and the instrument
panel hood was an exercise. Super stuff, but super stinky!
I made an absolutely
beautiful color interior color by mixing a semi-metallic Tamiya Gun
Metal with black, and used it on the Instrument panel hood. Then I
tried out the Hirobo rivets. Perfect spacing, and maybe of some
utility, but I do not think I will do the exterior with them....
We shall see. After the clear hardened, it is a thing of beauty!
I used the same color on
the inner door panels, with the same clear coat. The satin sheen
is perfect for interiors!
The Interior door Handle
came from SSM Helitechnik, and was just a rough brass casting. A
few minutes on a buffing wheel turned these into little gems. I
also made some plywood backers for the Vario hinges, so the screws would
have something besides one layer of carbon to bite into. The doors
are filled with epoxy, so they will have stout anchorages for the
After getting the doors
perfectly in place (actually, a bit high and canted forward to
anticipate a little drop from the hinge pin loading), I tape the
dog-snot out of them so they cannot budge, and drill the pilot holes
for the hinges. I have never found a better self-tapping screw
for this sort of work than the ones that came in the old T-REX 450
package. The screw kit gives you a couple dozen of these for $10
bucks... well worth it!!
Attaching the N52 grade neodymium
magnets takes non-magnetic clips! These puppies can pull the
nails right out of the frame of your house if you wave them around
(not really, but they are amazingly strong, even when separated by
multiple layers of carbon and fiberglass). A little Aeropoxy and
24 hours makes sure they will stay put.
Below, you can see the
door, hinged from the inside. The tiny protruding tips of the
screws in the door are covered with Starwood Rivet material to turn
them into rivets, the ones into the fuselage are sheared off with a
dremel, then sanded and painted to match the interior.
On the exterior, I start
filling and sanding gaps. We want a consistent gap, about the
thickness of a credit card around the entire periphery of the