After a lot of fitting and clamping I thought I had the door just right. So, I drilled it and decided to set a rivet. Once the rivet was in place, I removed all the clamps and closed the door to check if I had set the door correctly to the frame? I did.
The next step was to adjust the rotation of the door in relationship to the frame. That rivet acted as a pivot allowing me to adjust the side opposite the hinge up and down to get the perfect alignment. Once I achieved that alignment, I clamped the hinge at the bottom and drilled the very bottom hole. Then I set that rivet and removed the clamp.
Now, the door was attached to the frame and was free to move throughout its range of motion. I verified that the overall alignment was perfect. With the door attached, I was able to drill all the other holes. Also, I will be able to figure out the latching method and get it installed. I'll need to add stiffeners to the back of the door, probably in the form of a bracket to attach a first aid kit. Might as well pull double duty since I have to add them anyway.
Once completed and I move into the covering process, I'll drill out those two rivets and remove the door from the fuselage. After cover/paint, I'll reinstall the door and all the rivets during final assembly.
