Saturday, May 8, 2021

Flap system and tunnel cover work - 6 hours

 I need to re-do the F-785A backrest brace. Originally I had drilled it for the stock RV backrest, but then after installing the Almost an RV14 mod the holes are not the same. I'm sure I could leave it as-is and carry on but it bothers me to leave it like this. 



So, I ordered a new piece and began the fitup process again, but this time with the holes for the almost a 14 mod only. 


 After the backrest brace is all set-up and redrilled. The fit for the seat mod is turning out extremely well. I do have to mess a bit with bending the tabs on the stainless backrest crossbar to tweek the fit, but in the end a have an install I am really happy with. 



 
Now I'm ready to finish the tunnel cover. With the flap assembly complete, I've focused a bit on the final fit of the F-741A z-channels. There is a bit of interference between the rivets on the flap channel and the z-channel. I will have to remove some material so that these parts do not rub.

Next I need to fit and drill the F-741B cover to the z-channels. However I notice that the width of the cover as called for in the plans (2 3/4") is not enough to fully span the width of the tunnel cover. Looks like I am short about 1/8" on both sides. 

So..what to do. 3 options..1 - Leave it, 2 - Make new F-741A z-channels, 3 - Make a wider F-741B cover.  Ultimately since I have spare lengths of z-channel I went with option #2 and I have everything re-cut after about an hour worth of work. I started drilling the new holes for the #8 holes and drilled one too large with a 1/4" bit. Just not paying attention. So annoying. So I scrapped Option 2 and went with Option 3. I just made a wider F-741B tunnel cover. Hopefully this works and won't be rubbing on the seat. All else fails I can always make a new tunnel cover if ever needed.