After not getting very much done yesterday, I wanted to pick a simple project and blast through it today. I chose the access door for the ELT, and I got it mostly done after several hours of work. The goal was to create a door in the baggage floor that covers the ELT and fastens with latches that can be opened without any tools – I figure that might make a difference after an accident. The latches also have to be flush when the door is closed – this area will be covered with carpet, so protruding fasteners like these won't work. The last goal was to avoid sacrificing any of the strength of the baggage floor, despite cutting a big hole in it.
I started by cutting a blank out of 0.032" alclad and match drilling it to some of the screw holes in the left side baggage floor. This piece was the start of a doubler for the big hole I later cut in the floor.
I fashioned it into a doubler ring, using a unibit, snips, and files. Before it's installed permanently, I'll bevel the edges so the material of the baggage floor will lay over it properly.
Then I cut the hole in the floor, using the same method. The doubler has a 3/8" lip on three sides, and no lip on the side where the hinge goes. The hole looks overly large here, but you actually need this much area in order to get the ELT in and out and to give the latches a place to fasten. And yes, at this stage I did make doubly sure that I could finagle the ELT in and out through the hole.
I made a simple door out of more 0.032" and fit it for a hinge. I also fashioned some scrap angle into stiffeners that run along the front and back.
Test fitting the door. Notice that I doubled up on the screw holes around the door to reduce the amount of flex.
More test fitting of the door. The way the door matches the cutout in the area of the hinge leaves a little to be desired, but I'm not too worried since this will all be hidden under the carpet when people are looking at my airplane.
To keep the door closed, I'm using a pair of Hartwell latches. (Compare ACS's new price to their surplus price – ouch! Luckily I can get surplus ones locally even cheaper.) I only had time to rough out the hole for one latch, but it turned out okay. A little more filing and deburring and it will be done, then I'll do the other one to match. I wish Avery sold a drill bit that would make a square hole.
Here's a view of the back side of the latch. These are designed for thicker material, so I'm probably going to have to make some shims to make them flush with the top of the door – otherwise I suspect I would have latches opening inadvertantly when I put luggage back there.
My other project today was removing the blade from my mower and taking it to the hardware store to be sharpened. It won't be done till Friday, so that means I get to avoid mowing the hateful lawn, which is already getting pretty long, for yet another week. I can't imagine ever regretting that decision!
