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Permalink Reply by Matt Pope 18 hours ago

This seems to be a common problem on the pilot's side door, so unfortunately I doubt you'll find one. AC 43.13-1B has instructions for fixing cracks, section 4 - 3.40

I fixed mine by drilling a 1/8" stop hole at the end of the crack, which I filled with a slice of 1/8" acrylic dowel I bought on Amazon. I glued it with Weld On 3. Just make sure you get the sides of the crack lined up perfectly before the adhesive sets, and if it ends up uneven, don't try to sand/polish it flat or the optics will be slightly wonky around it (ask me how I know...). 

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Permalink Reply by Thomas Heiting 2 hours ago

Thanks Matt for the info !

Zenith could have definitely increased the structural integrity of the door in their design specs.

You are correct that it is a problem in the bubble door design.

If you have any photos of your repair please send them.

Thanks again for the help!

Tom

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