Cabin Top Permanently Attached

Needed to finish up a few things after the paint was done which are much easier while the top is on its back. One of those things was trimming the fiberglass substrate for the headliner. I did that by laying out paper to make a template, transferred it to the fiberglass and used aluminum sheers to cut it out.

Paper Template

Testing the fit on the right side.

The same thing was done for the left side.

Both fiberglass pieces trimmed and in place.

I then spent some time installing the Map lights for front and rear passengers, overhead lights, and the Aerosport headset and seatbelt hangers.

Front MAP lights
Rear MAP lights and overhead dome light
Closeup of the front

I also got the headliner material in a Graphite color laid out to have a look at it all together.

Overhead panels complete!

I then put the door strut brackets back in and tested out the McMaster seal. The seal is actually a little short.. I guess I shouldn’t have cut it exactly previously. I suspect the build up with micro and paint is to blame. I may end up ordering another seal to make it perfect, as this is something you see every time you enter the plane.

Sitting in the back seat observing how the overhead and paint came out

Then it was on to doubling back and finishing a few tasks that I had left prior to permanently attaching the top. I had left the #12 and #19 holes un-countersunk in order to use Clecos while finishing the doors. So I countersunk them per the plans, installed the HW (loosely), and then applied a Flox/Epoxy mixture with a zip-lock bag with the corner cut out in the gaps between the lower half of the fiberglass door frame and the metal structure. I then tightened all the screws and cleaned up the edge to make a nice fillet all the way around.

Left door floxed and bolted in place
Right side screw heads sitting flush in the door sill
Right door done too!

Now my plan is to work on finishing the transitions along the bottom edge of the door with micro to match the rest of the cabin top. Then I’ll be working on final gapping the doors and painting them to match the cabin top.

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