11.2. DOORS

Now its time to handle the doors:
1. Place the flap-up windows in the door, make sure they have an even space around it. It is very helpful to use pieces of cardboard around the window. Sometimes it is neccesary to file a bit off the front hinges as you can see on the picture. When the windows fit nicely you can drill the holes for the hinges. These holes not neccesarely match the marks in the door!
2. Mount the windows using the M4x12 screws and a washer and lock-nut on the inside.
3. The top side of the window is not sealed with a rubber but has a little clearance. Use a feeler gauge to check the clearance and file/grind the polyester if needed.
4. Mount the stainless plate inside the door, use a clamp to secure it to the window-sill and make sure the edge of the hole for the lock is situated on 200 mm from the edge of the door. (see picture)
5. Mark the hole for the lock and the 2 bolt holes and drill/file these. The plate can now be mounted. Make sure that when mounting the lock you use the felt gasket between the lock and the outside of the door.
6. Mount the hinge on the upper side of the door using the 3 M4 bolts. Make sure the rear end of the hinge is parallel to the rear side of the door.
Do not glue the hinge yet!
7.Place the tubular frame inside the door, make sure it fits neatly through the stainless steel plate and screw to the hinge using the 2 hex countersunk bolts. Measure the distance between the underside of the door and the tubular frame (outside measurement), this should be 50mm. Move the frame until this measurement is reached and drill the 2 holes for the handle. You can now mount the handle on the outside using the M4x40 bolts, place a washer between the frame and the polyester to create a bit of play. This is useful later on; if you want the door to close tighter after a while, you can remove the washers.
8. Place the rubber seals in the door, at the front of the window and at the underside of the door you stick the self-adhesive foamseal.