Originally Posted by
surfandturf
If I could watch how them put these on the aircraft on the assembly line just once I'm sure everything would make sense but that's obviously impossible being in the USA.
You could always go to the Airbus plant in Mississippi where they build the UH-72 which is basically an off the shelf H145. The 145 has the same door and fuselage door frame as a EC135. Regardless, the method I posted above has worked fixing 135 door issues to include swapping doors between airframes. As mentioned above, the upper guide arm plays a big roll in how that door opens/closes. At one time we had people use that guide as a handhold and we were always having to tweak the doors to shut good.