OK let's start by making the door fit just right.

This WILL require a LITTLE BIT of q-cell.. this is resin mixed with teeny little glass beads to make a mixture that is just like peanut-butter.. you spread that onto the plane and then sand it down. But, BEFORE we put on the q-cell, we wet the carbon fiber with resin so the q-cell can make a nice good bond to the carbon fober body.

OK so now we have added the q-cell, we ran a popsicle stick (!) around the seam of the door and body to come up with the perfect gap.

We will leave this alone for a little bit to let it PARTIALLY set...

Then we go in and take off the extra material, leaving a nice smooth body termination that is exactly 1 popsicle-stick width from the door, all the way around.

Then come in with a razor to make it nice and neat.

Once you have trimmed the filler there, leave it alone overnight to let it set... then, the next day, get on it with the sander!

Sanding is fun, because every bit of work takes off another few grams os uselsss weight!

My plane has very very little filler compared to other planes.

After a while, you can NOT stay clean with this job... but it is a pretty fun jobn I think. You have to work pretty darn hard, actually!

The guys at Lancair and RDD already had the door ready for me other than the bodywork above, but I loosended and tightened the door anyway, just so I can be sure that I have taken some part of every bit of construction I can, and so I know ever nut and bolt on the airplane.

Then you tighten and loosen the tensioners on each of the many chains on the door so all the little teeth close at the same time with a nice even bite as the door locks into place on the fuselage when closed.