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Jims RV-8
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Date:  12-26-2014
Number of Hours:  5.00
Manual Reference:  8-51
Brief Description:  Redo spacers / fuel gauge ramp

I received the order from Van's that had the F-802S-1 spacers included, so the first order of business was to replace those countersunk spacers. I could have let that slide as there was enough meat on them still, but as I was typing the email to Van's support to ask them if I should replace them or not, I decided it was worth replacing them. They were $5 parts, so it wasn't even a thought. I got them to the shop and re-drill the 1/8" holes, and then the #19 holes were drilled. I then smoothed the edges and put them in the sink for their EkoEtch scrub and physical etch. Then I blew them dry and primed them...then set them aside.

Next, I drilled the hole for the fuel selector. I started by putting a dab of torque paint on the top of the selector knob. Then I drilled a 1/8" hole. It was off a bit, so I moved it to the center as I drilled the hole larger and larger. I re-fit and re-drilled a few times and even used the nibbler to move the hole a bit. Then finished up on the drill press with the unibit to 1".

Next was the fuel gauge ramp. I tweaked it around with version 1.0, and when I had it where I wanted it, I decided I could make it better with an angled attach tab on the front side, and another attach tab on the aft side. I also wanted it to be a little wider. So, using ramp 1.0 as a template, I added in the extra dimensions and cut the new "blank". The aft tab is good to go, and the front tab is sitting under the fuel gauge face plate - I will trim that to size - closer to the attach holes. There will be 2 attach points at the front and two at the aft - independent from the fuel gauge selector.
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lower left console - drilled for fuel selector

lower left console - drilled for fuel selector

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pic after first bend

pic after first bend

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3 bends later - looking good.

3 bends later - looking good.

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