Sorry to harp on about this but there is good reason.
The book sets the bush to bush distance as 947 mm. (p10-31) . Unless you
measure it, you may not realise that the fuselage opening at the holes is
much wider, around 955 mm. So with the tips level with the bushes in the
open position, each bolt has to travel 4mm before even the tip reaches the
hole. This is no doubt to give some space to get the things into the frame
without hitting the paintwork.
Consider the scenario where the rear bolt only is out of the hole. If the
front bolt insertion were very large, then it could not leave axially. As
mine showed no hole damage it did, throwing the load on the hinges which
broke out the plywood inserts in the fuselage. More insertion might have
saved the day. Strengthening the hinge mounts is obviously the wrong thing to
do as an attached flapping door would be a monstrous hazard. The factory
recommend filing the tips back, still maintaining them flush with the bush
when closed. This somewhat erodes the centering action of the cone, but so
be it..
I would suggest (pehaps additionally) sacrificing some of the 4mm gap by
setting for almost that much protrusion. After all, the paint gets knocked
anyway due to the flexibility of the door far exceeding 4mm, and anyway
sooner or later someone tries to close the door with the bolts extended .
Both of these mods involve longer rods in the mechanism, which is a bit
traumatic if you have driven in the roll pins and expoxied on the cover, so
act early if you are going to.
Graham C.
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