Filler box sides fitment

[dbdevkc]

I am assembling the filler box to the upper firewall former on plans sheet F15. I am finding that the box sides piece that gets bent does not fit up to the bottom flange on the cutout in the former. The flanges on the box sides hit the flutes on the flange at the top of the firewall former. See photo - if I were to trim off that marked area of the filler box sides flange, then it would be able slide up the rest of the way and the bottom of this piece would then fit up against the flange at the bottom of the cutout in the upper firewall former.

Anyone else have this issue?

Kevin

[Bryan Cotton]

The big issue I had was the box was too small and the tank could not go forward all the way. See the last post, page 50:
viewtopic.php?f=39&t=578&start=490

There is a picture of my fuel filler box here and it looks like I did not cut that part out.

viewtopic.php?f=39&t=578&start=220

[dbdevkc]

I looked a little further and saw this note:

"Fuel filler box bottom clecoed on. I have 13 hours into this stupid thing. On my next Waiex I will make my own parts to the same design as the stock tunnel but 1/4" deeper. "

That is a good idea. I'm going to do some mocking up and see If I'm going to have the same issue.

[Bryan Cotton]

I am having a flashback now. I think I moved some of the flutes as they came poorly located. Just get a flute dragging tool and you will be fine. Or, if you don't want to invest, squash the inconvenient flutes flat and put them where you want them. The stainless is both strong and ductile and I wasn't concerned about cold working the flange twice.

[dbdevkc]

Ah, yes that would be very helpful for this and some of the flutes on the turtle deck formers also to get those aligned with the skin holes. I had never heard of a flute dragging tool - where can I find that?

[DCASonex]

My fuel filler section of the plastic tank was resting on the small edge surface of the filler box. Did not like that, made new slightly deeper filler box and incorporated an overflow or spill catch trough with drain. Also added 1/8" plastic shims on top of large angle that runs across firewall and supports forward end of the tank. Seems no two plastic tanks are exactly the same.

David A. Sonex (A) - TD