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ALAN'S WEB SITE
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Date: 2-26-2009
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Number of Hours: 2.50
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Manual Reference: DWG 19 - 31A
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Brief Description: Gascolator, doubler, and relays
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This puppy isn't going anywhere. The doubler that holds it on has over 20 rivets connecting it to the firewall and stiffeners. I actually googled the installation not believing I needed to install so many rivets. But, it's true!
First, I drilled out a key rivet in the firewall/stiffener. Then, I clamped the doubler onto the stiffeners and backdrilled through the rivet I removed.
- Drilled all of the #4 rivets in the stiffeners and clecoed the doubler in place. (Used angle drill)
- Drill through for each of the #3 rivets attaching to the firewall (I actually got to use the Boleube I picked up a while ago. Drilling into stainless steel is tricky. I also used an electric drill rather than the air drill. Slow is better.)
- After CAREFULLY deburring the holes. (This stainless steel it nasty stuff. I kept poking myself on the sharp edges.)
- Next came drilling for the gascolator.
- There are pilot holes so I drilled the two bolts holes first.
- Attached the gascolator to check fit.
- Drilled a small hole and the enlarged it with the step-drill. (Again, sneaking up on the exact size.)
- After I test fit everything, I shot a coat of primer on the doubler.
I also attached the battery box temporarily. (It looks pretty cool.)
I also started work on the master relay and starter relay.
Before I drill the bolt holes through the firewall, I want to make sure everything is going to line up correctly. I drilled two of the holes earlier. (These bolts holes are actually set by the placement of rivets in the stiffener.) The two inside holes are what I am worried about. The relays can be moved left or right but need to be lined up for the copper bar that runs between them. So, to help get the placement close, I fabricated the copper bars.
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Front view
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Inside View
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Testing the fit
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