Finished the filter/gascolator doubler - 1.5 hours

 Accessibility to dimple the doubler is difficult. I decided that I was going to use the rivet gun and a scrap chunk of steel to make the #6 screw dimples. I had ordered a chunk of steel from Metals Supermarket and will use that as a die holder/bucking bar. I had to clean up the steel and drill a hole to accept the female dimple die.

This setup is now used on the top side of the floor to allow use the male die in the rivet gun from below.

 Once all of the #6 holes where dimpled. I then used the pop-rivet dimpler to finish all of the remaining 3/32" holes.

Opened the vents on the Center Cabin Cover - 2 hours

 I'm a little tired of looking at that fuel system doubler, so I decided to jump over to the F-782C center cabin cover. I fitted and drilled the F-982D heat baffle to the cabin cover.

I need to open the vents up on the cover before I get too far. I have a piece of scrap angle that has an 1/8" radius outside edge (Left over from the seat backs) that I used. Drawing reference lines I then used the angle to open the vents.

 I used a piece of 1/4" oak as a guide to how much to bend the tabs. If the 1/4" oak fits into the tab opening...I am good.

 

Started final fitting of the filter/gascolator on the doubler - 2 hours

 Now that the hole has been cut for the filter/gascolator safety button has been drilled. I can re-install the safety button in the unit (Mock-ups with the unit are really difficult with that valve button installed so I removed it). 

I opened the mounting holes from 3/32" to #28 for the #6 screws. Then I started in on dimpling the rivet holes. Wow...I didn't anticipate how difficult the access is in this area. I just barely managed to get my pneumatic squeezer in that 2 1/2" opening. I used the squeezer to dimple all the holes I could. 

Finishing the filter/gascolator doubler - 2 hours

 Small night on the build. I took my time to do some final sanding on the large 2 1/2" hole to get the fit of the Aerolab unit just right. 

 Next I used the stainless steel template to make the 5/16" hole for the safety release button. I did not use a drill bit for this hole since I have already cut the 2 1/2" hole...., however the stainless template was a great guide to open up that hole with the use of files and the dremel.  

Making the filter/gascolator doubler - 9 hours

 Big day on the build, but unfortunately not a whole lot of progress. I want to place a doubler under the Aerolab Filter/Gascolator. The floor is thicker aluminum (0.040") however there still is some flex in the floor and that may add stress to the attached rigid fuel lines. My thinking is that a doubler will reduce flex and stress on the fuel system when I'm climbing in and out of the plane and also when servicing the gascolator.

I need to finish setting the correct location of the gascolator based on my new j-tube. It's just a tad further aft than my original position.

 I have the stainless steel template for the gascolator and I am able to drill the exact center of the unit.

Now comes the fun part...I've previously settled on a 0.032" doubler. It allows the bottom of the Aerolab cap to sit perfectly flush with the bottom of the floor skin. I cut out a square doubler shape and started "making" the doubler. 

After placing the template on the doubler, there is no doubt in my mind that this does not look good. First, I don't care for the doubler to be off center, and the round unit on a square rivet pattern just doesnt work. 

After talking with my buddy Mike (A local builder) and diving into the Standard Aircraft Handbook it inspired my to attempt a different doubler and rivet patten. While I won't have the recommended 6D spacing of rivets in all locations. I think the more radial pattern of rivets will work really well.

So I drew the pattern/template on CAD and printed it out. Its looking good. So I then cut a new doubler plate and using the CAD template I drilled all of the holes 3/32". Since the pattern and fit just work...There was no hesitation to start drilling the gascolator mounting holes through the floor skin.

Satisfied with where I am at, its time to drill the 2 1/2" diameter hole for the Aerolab unit. Drilling these holes with a holesaw is always a stressful event. My holesaw is not a precise tool and it likes to wobble...So my method to prevent this is to make a cutting template out of wood. This helps keep the holesaw in the correct location and makes a clean hole. Using 1/4" MDF...I went to work.

The hole in the floor is correct, just need to repeat the same hole in the doubler.

Once done, I am now ready to drill all rivet holes in the doubler/floor skin.

Completing the fuel line from the gascolator to fuel pump - 5 hours

 I purchased a piece of 1/4" MDF as a platform for the fuel pump to set on. It is very close to the correct height of the tunnel cover. I'll save you the long details, but basically Tom's 'samples' provided an excellent model to follow and I was able (after a few tries) to get the right geometry figured out to get a tube bent that fit excellent and also allowed the fuel pump to sit as far aft as I can get it. 

Fitting custom fuel lines from TS flight lines - 2 hours

 My order from TS flightlines arrived and they do look great. I ordered a custom J-tube and an S-Tube to fit the Aerolab gascolator. They do look great and the tight radius are really good. However I soon found that the J-tube interferes with the spar when fitted to the stock position of the fuel selector hole.

My thoughts circled to making a new fuel selector plate and pushing the selector switch forward which then fixes the issue of the spar. However, the J-tube itself is too short in height. The selector plate would have to be lowered quite far to make it work. Looks like its about 3/8" short in height.

Unfortunately I won't be able to use any of these. Its a shame. Tom at TS flightlines was so wonderful to deal with and the workmanship of the tubes is great, but unfortunately his RV setup and mine are just too different.

Tom's pieces did give me the information I could then use to fashion my own custom tubes. Using the now 'samples' I fashioned my own J-tube. And the fit is excellent. Albeit not as tight as Tom can get to but I can work with what I got.