Title: Door Handle Mechanisim
It's taking some time to understand how the Door Handle Mechanism goes together, but I'm finally getting the idea. Starting with the AeroSport instructions, they have you cut the WD-1022 Handle and C-1007 Pin to accommodate the new mechanism. Then follow the Van's instructions to install the C-1008 Handle Lever, which controls the door lock, and roll pin spring. Thanks to very long and skinny needle nose pliers to position the nutplate inside the Handle Lever and rivet it in place. The forward corners of the strike plate must be rounded to let it nest flat. The strike plate is used as a guide to make the holes in the door shells. Then match drill and rivet the handle plates which will attach to the new delrin spacer bock. Drilling the holes in the door shell was straight forward but a little nerve wracking as the space between the 0.25” holes and the new 0.90” lock hole is very thin. I'm using the ACS door locks and at first fit, i thought they were too short. I didn't notice that the 0.90" hole allows the lock to rest on the strike plate and once the cover plate is installed, the lock will be flush. This door handle is a very nice addition and I'm happy with the installation. Next step is to install the forward and aft door pins. The aft pin needed to be bent to parallel the bottom edge of the door shell. I just bent it by hand in the vice. The forward pin is much more short, so was a bit more difficult to bend. Finally, i painted the inside door shell with the same SEM Texture Coat then the final Lite Parchment Color Coat.


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