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I completed these several months ago. The latching system and gas strut installation was another task that took way too much time. I built the frames from 20mm square carbon tubes. The frames by themselves weigh 3# each. That is a 6# savings each compared to building them from 3/4" steel tubing. I used the hinges that would have been used for the windows. To reinforce the attach points in the carbon fiber, I inserted 1" pieces of 5/8" square steel tube into the upper tube before connecting the tubes. I purchased Suspa gas tubes from Amazon to support the doors. 17" extended, 10 3/4" compressed. I initially used 20# struts that provided marginal support. One tube by itself would slowly collapse. Went with 28# struts that securely support the door. Hopefully will be able to taxi with the doors open. I used the Hendricks latches which are expensive but very well made. Figuring out the arrangement of the locking rods and levers took me a long time. I initially tried to locate the hole for the forward rod too high on the sheet metal former. It interfered with the vertical tube. My goal was to have the rods at 90 deg to the structure so the bushings would sit flat. It took me quite a while to realize that I could accomplish that by slightly bending the rods. Hendricks sells pre made rods and links. You need to make your own. I found the best price for the 3/8th aluminum rod and 1/2 x 1/8 aluminum bar at wicks. For closing the door I think a handle separate from the latch handle is needed. I couldn't find a suitable one so welded one from 3/8th steel tube. For the door trim, I laid up carbon fiber in place. It is one piece. It attaches with #8 screws through the trim, plexiglas and into drilled and tapped holes in the carbon fiber tubes. I learned that was possible from Mike Patey, initially thought I would need long screws through the tubes. Plexiglas is .100, think that will work with the cross tube providing additional support. Total weight of the doors is 9#. Would I recommend others build their windows, doors etc with carbon tubes. That's a definite no. While it was nice to save 12#s, the extra time and expense was not worth it. I am going to love the view out of the full plexiglas doors.
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