Building the Glen-L HOT ROD - Jump seats and fuel tanks - Page 2
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Click to enlarge. Port side seat support completed.  (16-JUL-2009)

Click to enlarge. 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.

Click to enlarge. 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.

Click to enlarge. 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.

Click to enlarge. #10-20 machine screws are fastened from the bottom so they can be removed from the bottom. 

Click to enlarge. 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)

Click to enlarge. Loaded fuel tanks will be quite heavy, so we laminated two 1-1/2" ledger strips to the side of each cradle.

Click to enlarge. Fuel tank weight will be distributed to the top of the frames.

Click to enlarge.  

Click to enlarge. 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)

Click to enlarge.  

Click to enlarge. The electric fuel pump and fuel and water separator filter were fitted to the starboard seat base partition.

Click to enlarge. 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)

Click to enlarge. Here's a view of the forward jumpseat bulkhead looking aft.

Click to enlarge. Fuel fill blocking was laminated from marine grade plywood and Douglas Fir stock.  The plywood layer prevents the Fir from splitting.   (14-JUN-2010)

Click to enlarge. 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 !

Click to enlarge. Deck sheeting was cut out for the fuel fills.  (19-JUN-2010)

Click to enlarge. A 1-1/8" hole saw was used to install the two bilge pump thru-hulls.  (19-JUN-2010)

Click to enlarge. 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.

Click to enlarge. 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.

Click to enlarge. Here's a better view of fuel vent hose ...

Click to enlarge. ... and the fuel fill hose.

Click to enlarge. 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.

Click to enlarge. Stainless steel fuel vent fitting completes the fuel tank rigging !  We'll be taking our fuel tank mockup into a welding shop next week !

Click to enlarge. 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)

Click to enlarge. A stainless steel piano hinge will complete the assembly.

Click to enlarge. 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)

Click to enlarge. 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)

Click to enlarge. 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.

Click to enlarge.  

Click to enlarge. 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)

Click to enlarge. The distributor's MSD ignition box (blue box) mounts to the side of the electrical box with rubber vibration dampers.

Click to enlarge. A stainless steel piano hinge was used to hinge the electrical box door.

Click to enlarge. 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 !

Click to enlarge. 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)

Click to enlarge. The 2" fuel fill hose is directly below the deck fill fitting.

Click to enlarge. 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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Building the Glen-L Hot Rod :      Revised 24-JUL-2011