Because I raised the door thresholds for the gull wing doors, I needed to fabricate some additional aluminum panels. The AviPro Bearhawk kit also comes with aluminum threshold caps that I modified to serve as wear plates. Those are typically fabric covered. This section will have three panels assembled with #6 button head screws and nut plates. This will allow access for inspection and maintenance of the fuel lines.
I recently look over a Aviat Husky with similar overlapping side panels. The owner showed me how he protects the paint on those panels using 3M Windo-Weld.
A thin layer of Windo-Weld is applied to the area of the panel that overlaps the painted panel.
Masking tape keeps the lines clean. Just pull up the tape while it is still wet and allow to thoroughly dry.
I cut holes in the shaped cedar used to raise the threshold. These holes will accommodate the nut plates attached to the back of the panels that will be installed behind the threshold caps.
Panels have been sized, cut and cleco fastened.
The most rearward panel wraps under the bottom longeron. Since the kit does not account for aluminum this far aft, I created a mount using aluminum angle and adel clamps. To hold the adel clamps and prevent from "rolling" by the pulling force of the panel, I wrapped the adel clamps and angle with small pieces of fabric and glue; effectively locking the piece in place.
With 3/8" #6 screws. The top row will be flushed.
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