Building the Third Door Modification on a Challenger

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Windscreen laid out on the wife's favorite blanket to prevent scratches

Sanding rough edges.  Watch out for possible flash from bald head if the next two pictures are enlarged.

When fitted to plane 1/8 inch holes were drilled.  Enlarging one size bigger to allow for movement in rivets.  Helps prevent cracking

Installing 1/2 inch tubing for third door.  Tubing is easily bent to the contour of the windscreen from the outside.  Then cleco in place on the inside.

All 1/2" tubing bent and clecoed in place

View at the center cap.  The windscreen is attached to a 1/2" tube bent the shape of the center cap.

Gussets photographed on the jib used to bend all the tubing.

Hinges cut from a 6 ft. piece of piano hinge.  Hinge length is 5"

Cutting windscreen just far enough to fit hinges. 

Putting it all together

Removing one cleco at a time to ensure everything stays in place.

Door is temporally mounted for final check before continuing with install.

The answer to the problem of latching the door securely came in the Challenger kit. It's part of the regular door kit used to secure the doors in the open position.

Having some of the same material from my wood working days I used the band saw to cut the shape of the top rail.  Drilling through the 1/2" tubing and the gusset the latch is secured.

No other trimming was needed and things fit like a glove over the side rail.

Side rail wear guard

The latch is firmly secured by locking it behind the rib.  It snaps in place and holds just enough tension to slightly bend the Lexan against the side rail.  See previous photo.