Main Door
The main door was made first. The rectanguar windows looked funny so I increased the cutout and applied carbon patches top and bottom.
A dual latch was installed, connected by a pushrod, with a single lever on the outside of the aircraft. The handles were cut from 6061-T6 aluminum, and the latch pin is 3/16" diameter 304 Stainless Steel. The holes for the shear pins were a pain to drill - I went through a few 1/16" drill bits and over a foot of stainless rod (at 1 1/2" per attempt).
A door jettison system was installed, with a single knob releasing the four clevis pins holding the door to the hinges. Springs fire the clevis pins outward and the door is free to fall away. It works quickly and reliably.
