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CharlieWaffles 06-04-2012 03:59 PM

Door Threshold Ideas
I'm starting to look at the door threshold and wondering what the best way to finish this area is. When the door is opened, the canopy top has a flane from the door threahold sticking up to meet the bottom of the door. It isn't very thick and then quickly drops down to the horizontal aluminum threshold piece that canopy is attached to. Seems it would make for better cosmetics and a place to step if the threshold was filled in and leveled with the the flange. I know the factory plane has a cheap looking piece of wood cut to fill the space.

What are other people doing? I'm considering having my machinest mill me a hallowed out piece of aluminum that fills the space and doesn't weigh much.

Phil 06-04-2012 04:25 PM

Expensive piece of wood.

Bill.Peyton 06-04-2012 04:32 PM

Don't sweat over it. It is real easy to get a great looking transition. Make up a mixture of micro balloons and epoxy resin peanut butter consistency. using a cake decorator funnel, squeeze the mixture into the area under the threshold and using your finger, make a nice transition. You may have to come back a second time with more filler and then sand with 80 grit, fill with a little strand reeforced body filler and paint. It will look great after you paint it to match your interior. Sorry, but i do not have any finished photos, but hear is a photo prior to paint.

douglassmt 06-04-2012 04:56 PM

Me too
I did what Bill did, sorry don't have any good pictures.

I thought I might want an armrest there like in N410RV:

However, I found that my elbow/arm is well above it so it doesn't make sense for me to have an armrest there, and I've never thought about stepping on that area, although I do sometimes put my hand there when climbing out. So I just finished it and painted it. Works great.

Oh, and if you use McMaster Carr seals, you'll want to leave space between whatever you put there and the cabin flange to allow for the seal grip. Another reason to not put anything there.

Mike S 06-04-2012 05:02 PM

Mine has a piece of wood fitted to the area, it will eventually get covered in the same material the rest of the interior is done with.

N15JB 06-04-2012 06:11 PM

My panel is cherry veneer, so I considered using cherry for the sill. Wound up doing what Bill did, and now that it is painted it looks great. I haven't completely given up on making a cherry sill, but really don't see the point.

Jim Berry

Bill.Peyton 06-04-2012 09:05 PM

I found this photo at Geoff Combs site. This how it looks when it is painted.

CharlieWaffles 06-04-2012 09:07 PM


Expensive piece of wood.

I was indeed looking at a wood or solid material to make the threshold wider and easier to step on like the factory. I have a nice fillet around the door already so I'm not worried about the transition, just the thin flange that I know someone will try to balance on when they get in or out someday.

Phil 06-04-2012 09:28 PM

Seriously. That's my plan with a expensive piece of nice hardwood.

Cut it close to size. Sand it to fit. Stain it. Urethane it.

I don't know if I'll get it done before the plane takes to the air, but it would be a good rainy weather project. It's not worth delaying the build over.

But I really don't want folks to be able to step on that edge either. Having that piece of wood there will pickup most of the load and keep them from standing on that edge. (and did I mention I have kids? They will step anywhere they feel like it and they won't be gentle about it.)


Bill.Peyton 06-04-2012 09:59 PM

Just don't let anyone step on it! :eek:

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