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Date:  5-24-2020
Number of Hours:  5.00
Manual Reference:  21-05
Brief Description:  Sight gauges and strake top skin preparation

Hot glued some plastic packers to the underside of the luggage cut out tops to support the top skin when installed. Trial fitted all this with some foam.

Made the next generation of fuel sight gauge jigs from 20mm OD PVC tubing and drilled trial pickup holes. This did not go well and there are some holes to patch.

Cut first gauge from Schedule 40 clear PVC tubing for the sump tank and experimented with feed tubes. Final design is 33mm long, from 3mm OD brass tubing. Cut 6 and prep sanded.

First one worked by luck, but subsequent ones were better, I drilled some experimental holes in the PVC jig and inserted some 3mm carbon fibre rod, and superglued it to the jig. If this could not be withdrawn easily I removed and adjusted the alignment of the rods until it did. I then made an alignment jig out of a couple of window wedges taped together, with a 3mm spacer on the side. I smeared some bondo where the tubes will go, covered it with plastic film wrap and clamped on the jig with its rods. When cured I levered it off and this gave me an alignment jig for drilling the tubing and floxing in the feed tubes. Which I did.

Applied PVA release to the inside of the cover of a lid from a packet of dremel exploding cutting discs, 2/3 filled it with wet EZpoxy flox and bunged it on the end of the first gauge. taped it inside a margarine container with a bolt taped to the bottom for stability, and placed it on a level surface, (my micro container), inside my epoxy cabinet for cure.

Cut three level indicator beanies from 1/4" PVC, impaled them on a pin, painted them black with Posca pen, dipped them in EZpoxy and fixed to a bit of cardboard, and into the epoxy cabinet to cure.
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Screwing up the first feed tube hole...

Screwing up the first feed tube hole...

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Carbon fibre feed tube jigs

Carbon fibre feed tube jigs

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From the inside. Kitlog doesn't seem to understand portrait format...

From the inside. Kitlog doesn't seem to understand portrait format...

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