[David Dunlop]

I got back to working on the DOORS assembly on the Sender today as well. Turned out my procedure for the PLATES, Phenolic, Calibration hardware came in handy with reinstalling the DOORS also.

My plan for all the hardware was to stuff enough paper towel into my ¼-inch Quarter Drive socket to get the hex nuts sitting just flush with the end of the drive socket, rest the lock washer on top and with a slotted screw driver already securing the screw from the top, move the socket with the hardware in by my fingers to engage the end of the screw. Then run the screw home. It worked perfectly for the inner three sets of hardware. I had forgotten, however, that the two outermost sets of hardware are in much closer confines and this approach would not work for them. So I went back to the finger-gluing plan with my left index finger this time.

Problem solved with the reinstallation.

An interesting discovery surfaced, however.

The lower Cowl fastener on the door had a broken Cross Pin in it and did not fully engage the receptacle mounted on the side chassis. It now locks home in a quarter turn just nicely. This fastener is the replacement Dot made cowl fastener that was installed on the Door at some point in the Sender’s history.

The Cross Pin on the upper cowl fastener was the correct length, but offset to one end and this longer end bent down a bit, away from the door. With the new Cross Pin in place, I discovered why the upper Cross Pin was the way it was.

The upper Cowl Fastener, appears to be too short a length: about the thickness of the cross pin from what I can tell. Instead of engaging the groove between the two receptacle spring plates, it is riding along the upper, outer, spring plate. Whenever this Cowl Fastener was installed, it must have been an ‘available’ replacement and the new cross pin was bent deliberately to make it work. I am going to leave it as is, for the time being. I have not found enough information to date to fully understand how the sizing codes for the Shakeproof Wing Head Cowl Fasteners work to know what exactly is needed.

David