Started the custom fuel pump cover - 2.5 hours

 With the FlyEFII fuel pump and the Aerolab Gascolator I just won't be able to fit everything under the stock doghouse cover. I will need to make my own custom cover. I order to do this, I'll use the stock cover that I have as a guide and make a longer (shallower) version. 

 

I cut the forward fuel access hole out in the reinforcing plate yesterday. I can now get clamps in to hold everything in the right spot. I could then start sketching out all of the lines to determine the rough dimensions of the cover. 

First, I need to make the sides of the fuel pump cover. I choose to use the same 0.020" material as the stock cover. I basically need to cut out a long rectangle and bend one edge with a 90deg flange. 

I clamped the piece to a table and then using a piece of oak with a 1/8" radius, I began the 90 degree bend for the flange. The initial bend is done by hand, with the final process being a rubber mallet. I made both the left and right side covers this way.