Building the Glen-L HOT ROD - Jump seats and fuel tanks - Page 1
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The following photos depict construction details for the rear jump seats.  A custom-built ten gallon aluminum fuel tank will reside under each seat.

Click to enlarge. Building a form consisting of a piece of 3/4" plywood over the starboard-side seat frame.  (21-JUN-2009)

Click to enlarge. Pieces of scrap 1" x 6" spruce lumber were slipped into place to define the vertical surface.

Click to enlarge. A 1/4" gap was left between the seat vertical and bottom edge of the carling.  Side piece was inset 1" from the carling's outside face.  In the foreground, you can see our custom-built transmission shifter arms and linkage.  More on this later !

Click to enlarge. Several pieces of 1" x 6" stubs were used to define the shape.

Click to enlarge. Building this form reminds me of when, as a kid, my Dad and I used to build HO model train tables.  With a bit of fiberglass screening, plaster of Paris and paint, this would make a great railbed for a river trestle approach !

Click to enlarge. We produced 1/4" plywood templates to accurately reproduce the required parts.

Click to enlarge. The mold was affixed to the router table and covered with 6 mil plastic before applying the laminates.

Click to enlarge. First lamination was a .100" mahogany veneer followed up with 1-1/2 ounce chop strand mat and topped with a layer of 8 ounce woven roving.

Click to enlarge. The flanges on either side of the lamination consist of woven roving topped with a 1/4" plywood flange which was used to compress the fiberglass and impart some strength to the flange.

Click to enlarge. Here's the part after we've pulled it from the plug.  Total weight is less than one pound. (29-JUN-2009)

Click to enlarge. Edges were trimmed and the part was given a light sanding before coating with West Epoxy catalyzed with 207 Special Coating hardener.  Aluminum clips will be used to retain the top flange to the carling.  The lower flange will bolt to the seat bottom.

Click to enlarge. Casting was a success !  The piece fits like a glove and conforms nicely to the carling's lower edge.

Click to enlarge. Ends were left long so that they can be trimmed after installation.

Click to enlarge. The starboard seat base was installed.

Click to enlarge. Front partition was bolted to the frame clip at frame # 3.

Click to enlarge. Rear partition was bolted to the motor stringer with an aluminum angle.

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Building the Glen-L Hot Rod :      Revised 03-JUN-2010