Hey Rob,
A picture would help understand your issue, but I would hold off on sanding the
door as a last resort -- you don't want that to be too thin.
Without seeing it and if I understand you correctly, a 32nd or two can be pulled
down by the hinge, and even fine tuned by sanding the hinge seat. If the hinge
installs with no binding, etc. and you still need perfect flush, I'd recommend
building up the cabin surface with epoxy/flox, then sanding that to the door
surface, rather than sanding the door. Just make sure you feather out a wide
enough area so that it disappears when you prime later.
You might want to check out the archives here for Deems way of doing his door gap
rather than the Van's 45 degree approach. That would also help smooth out
any level differences.
Also, many are temporarily adding the weather strip of your choice before final
tuning of your flush fit, since it can change. Ours didn't, but that's a lot
of obsessive futzing around only to have to change it later!
Later, - Lew
--------
non-pilot
crazy about building
NOW OFICIALLY BUILDER #40549
Painting done!
On with wiring and avionics.
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http://forums.matronics.com/viewtopic.php?p=273172#273172
