Port side seat support completed.
(16-JUL-2009)
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Aluminum angle clips were bolted through the rear cockpit carling to carry the
seat support. Bolts were countersunk and epoxied to prevent the heads
from turning. Wood plug bungs conceal the bolt heads.
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The aluminum clip mates to the seat support flange. We've inset
the seat support 3/4" from the carling's inside edge. This will
allow room for padding and upholstery.
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We didn't want the upholstered panels to have any exposed fasteners, so we drilled
the clips for aluminum Sert-A-Nuts. These are similar to blind rivets, but they're
threaded to take machine bolts.
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#10-20 machine screws are fastened from the bottom so they can be removed from the
bottom.
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The fuel tank cradles were built from 1/4" marine grade plywood sandwiched between
a layer of 2 ounce chopped strand mat and 10 ounce woven roving laminated to both sides
of the plywood. Building the cradles from aluminum stock would have been way quicker but
the added weight would have required more flotation. Parts are lighter than aluminum and
they float !
(19-JUL-2009)
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Loaded fuel tanks will be quite heavy, so we laminated two 1-1/2" ledger strips to
the side of each cradle.
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Fuel tank weight will be distributed to the top of the frames.
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Parts were barrier coated with several rounds of West System epoxy, prepped with
Dupont UroPrime 2K primer surfacer and topcoated with Dupont Imron urethane.
(04-AUG-2009)
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The electric fuel pump and fuel and water separator filter
were fitted to the starboard seat base partition.
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Final assembly for the Port fuel tank cradle and forward jumpseat bulkhead. Cradle bolt holes
were bushed with fiberglass bushings. Sert-A-Nuts were installed flush on the inside face of the cradle
flange.
(03-JUN-2010)
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Here's a view of the forward jumpseat bulkhead looking aft.
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Fuel fill blocking was laminated from marine grade plywood and Douglas Fir stock. The plywood layer
prevents the Fir from splitting.
(14-JUN-2010)
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A stainless steel 2" fuel fill will feed the 9.2 gallon fuel tank. The white plywood box is a
mockup of the tank. Also visible in the photo are the hydraulic steering's annealed copper tubing
lines. It's a very tight installation !
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Deck sheeting was cut out for the fuel fills.
(19-JUN-2010)
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A 1-1/8" hole saw was used to install the two bilge pump thru-hulls.
(19-JUN-2010)
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Hose barb will take a 3/4" hose. Also visible in this photo are the two 3/8" annealed copper tubing
hydraulic steering hoses. They're retained by bulkhead fittings bolted through the steel transom support uprights.
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The large white box is a plywood mockup of a 9.5 gallon fuel tank. A 2" fuel fill hose can be
seen on the right of the photo. A 5/8" fuel vent hose with a high coiled loop is on the left.
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Here's a better view of fuel vent hose ...
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... and the fuel fill hose.
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The vent hose was routed to the sheer. Hose should be run 'downhill' so that water can't
find its way back into the tank.
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Stainless steel fuel vent fitting completes the fuel tank rigging ! We'll be taking our fuel tank mockup
into a welding shop next week !
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We built up the jumpseat's leading edge with a piece of 1" x 2" stock and radiused the top edge before
laminating both sides with 10 ounce fiberglass cloth.
(09-JUL-2010)
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A stainless steel piano hinge will complete the assembly.
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Our custom aluminum fuels tanks arrived on the 23rd. The 9 gallon tanks were fabricated at a local
welding shop in Ottawa, Ontario. The tanks were on back-order for some time now. We've been
holding off on final assembly until they were installed. Let the assembly begin !
(26-AUG-2010)
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We'll be installing the fuel tanks using David Pascoe's method. Complete instructions are
included in this article :
How to Install an Aluminum Fuel Tank.
The 1/4" thick fuel tank mounting pad was fabricated by laminating a fiberglass sandwich consisting of 6 layers of
2 ounce chopped strand mat between two layers of 6 ounce cloth. Once cured, we cut the composite into 2" wide
by 16" strips.
(31-AUG-2010)
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Tank bottom was roughed up with 40 grit sandpaper, washed down with Wash & Wipe wax, grease and silicone
remover, The strips were bonded to the tank with 3M 5200 adhesive.
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Port side fuel tank was placed on its cradle and the jumpseat panels were installed. The cockpit
coaming is ready for another round of clearcoat.
(04-SEP-2010)
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The distributor's MSD ignition box (blue box) mounts to the side of the electrical box with rubber vibration dampers.
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A stainless steel piano hinge was used to hinge the electrical box door.
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The electrical box is very cramped but we managed to pack a Blue Sea Systems marine rated fuse block,
a solenoid-actuated master disconnect switch for the battery and an electrical fuel pump relay. We'll
sort out the mess of wires when the engine is installed !
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The 5/8" rubber fuel vent hose has been looped to form a high loop before its routed to the sheer mounted fuel vent fitting.
(13-JUL-2010)
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The 2" fuel fill hose is directly below the deck fill fitting.
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Here's a closeup shot of the unswitched 12 volt fuse block. This provides circut protection for the automatic
bilge pump and any accessories that require unswitched 12 volt power.
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