Brief Description: Cooling Hoses and Cooler Box Door - CRAP!
Page 49-02 Cut two hoses to proper length. (step 1) Noticed that both springs were the same length as the 20 inch hose so had to shorten one spring to 17 inches to get the 1 inch insert dimension. Deburred the ends of both springs. (step 2) Was dreading the task of inserting the springs into the hoses based on frustrations from other builders. I don't know if Van's changed the dimensions of the hose/spring or not but insertion was a non event. Springs were tight but had no problem inserting them with a slight twist. (step 3) Created the cooler box hinges from MS20257C4-4 stainless steel hinge. Created hinge pin. (steps 4 and 5) PAGE 49-02 IS COMPLETE
Page 49-03 Match drilled hinge half to cooler box door, disassembled, and deburred. (steps 1 and 2) Dimpled all #40 holes in cooler box door and machine countersunk holes in cooler box hinge. (steps 3 and 4) Riveted cooler box hinge to cooler box door. Riveted cooler box bracket to cooler box door. (steps 5 and 6) Clamped and match drilled cooler box hinge to cooler box face, disassembled, and deburred. (steps 7 and 8) PAGE 49-03 IS COMPLETE
Page 49-04 Realized real quickly during step 1 that I screwed up match drilling hinge to cooler box face. When aligning both to the firewall, holes were misaligned. Drill bits were a bit dull and while pressing down on the bit into the stainless steel, the bit walked through the holes in the cooler box face. CRAP! Called Van's and ordered a new cooler box face and cooler box hinge.
