Remove the gap seal cover to expose the header, where your doors attach. .	.I started with 12 feet of .035 x1/2 in alum. you don't need this much but sometimes you will make a bad bend.
Make a curve to connect the header tubes. use small pins made from tubing cut long ways, to join the header to the curved part.	Tubing is cut to length for new door. Thanks for the help Sue.
Windshield is scored with knife.	Windshield is riveted to brace.
Lexan is torn at scored line. Much better than cutting.	Fairing is installed.
Tubing for new door is bent on jig.	Top of brace is sized and cut to length.
Gussets are cut and painted, if necessary.	Back edge of door is riveted and top brace is installed.
Tubing takes a few bends and cuts to fit properly.	Front windshield piece is riveted to new braces.
New holes in brace are drilled.	Two hinges are attached to new door.
Inside gussets are riveted to frame.	Bottom door brace is sized.
Bottom brace riveted.	Existing back brace is cut and door moves freely.
Bottom gussets are installed.	Bungee cord holds door securely.
Top locking latch is installed.

Explained a little better.....

Remove the gap seal cover to expose the header, where your
doors attach.

I started with 12 feet of .035 x1/2 in aluminum  you don't need this much
but sometimes you will make a bad bend.    Make a curve to
connect the header tubes. Use small pins made from tubing cut long ways,
to join the header to the curved part.

Attach the curve to the header. this is where you will attach the
windshield frame.

Cut 2 pieces to length.  You may need to mash the ends so they will fit
between the windshield and nose.

Install one tube and rivet in place.  This will keep the windshield in
place.

Use a sharp utility knife to score the windshield along the tube you
just installed.

Now you can pull the lexan apart. Save this piece as it will become
the door.

Reinstall the gap cover and attach the windshield as it was..

Now you can start to build the door.

Build a frame around the piece you just pulled off. this will require
some bending and building some gussets.

Attach the door hinges whenever. This will help in fitting the door on
as you build the frame. Use the factory hinges,  A piano hinge will not
work!  You can get hinges from the factory.

When you put on the gussets use Stainless Steel short rivets.

Do some more bending and attach to the door.

I had to paint everything black to match the customers plane, you
can do whatever.

This is the door done, now we need to make some latches.

With the door open it is easier to install the gussets.

Bottom door latch. 

Top door latch. 

 Any questions feel free to call me I will try to help.  If you fly into
our airpark I will do this for you.  Takes one day, about 5 or 6 hours.
I charge $150.00 + material.
 

Jim at a Erie place.