I Can't Believe It . . .

A whole week trimming edges, fitting "centa-flex" hinges, silicone sealing every joint and seam and still only just over half way through fitting the "pinch-weld" compression seals.
However it looks as if one more day will see that done (oops I forgot some work came in today) and then I can fit the doors to the bays and the locks to the doors and then, and then, and then I can start making the striker plates for the door locks to actually close against.
It just goes on and on and on . . .
and I want to get to the interesting stuff like fitting out and electrics and . . . wait a minute I still have windows and main doors to do before it is waterproof . . . aaarrgghhh !!
Any way this is what the doorlock looks like when fitted in position.
I think it will look OK . . .























So these are the processes for getting to the finished door . . .

fit the hinge


















and mask up for silicone sealing and fill the gaps with silicone


















I discovered after the fact that the hinge needs to be trimmed back on the corner for ease of opening and closing so when the silicone has set it needs to be ground off























seal up the corner which will be under the pinchweld seal from this


















to this.


















I didn't try and weld these as the angle was fitted to the frame and if the weld penetrated to the inside it would be very dificult to clean up.
As you will see there isn't much room for the seal . . .
So cut some pinchweld a little too long for one side and fit it too a temporary piece of angle


















Hold it in position with another piece of angle cut to the correct angle


















and cut the soft part with a trimming knife


















and then (I hope "Worksafe" never reads this) put it in a drop saw fitted with an aluminium cuting blade (as this stuff has a lot of bits of aluminium moulded into the "pinch" part to enable it to get a grip on the frame)























and trim off the bit not wanted.
It seems a bit tedious but if you try to just cut it in the saw the soft part of the seal distorts and gets cut at the wrong angle or it just gets ripped up.
So it looks like this


















This gets put back on the frame so it can be marked for correct length and the whole process repeated for the other end.



































Some special contact adhesive is applied to all ends and when appropriate the pieces are all fitted back onto the frame and pressed together


















Repeat for what seems a never ending series of doors . . .

Why did I think I needed this many???