Past two weekends:
Some place in the woods. With the van, who needs a campground?
West Virginia in the foreground and Virginia in the distance.
Heater Fuel Tank continued:
With the fuel hose trimmed to the proper length, need to attach it to the fuel inlet and seal up the hole in the rocker panel with a cover plate.
The problem is that with the fuel tank in place there isn't enough room to get my hand up between the tank and the rocker panel. I'll need to locate where the fuel hose is positioned so when I install the cover plate I can duplicate that position without the tank being in place.
I'll use the combination square.
Keeping the bubble level place the ruler against one side of the hose then mark on the rocker panel. Do the same to the other side.
That locates left and right. To measure the other direction I placed the end of the ruler against the bottom center of the fuel hose. I measured it with the tank but removed it for this picture so it's easier to see.
With the ruler against the hose, slide the square head up against the bottom edge of the van while keeping the bubble level. Then lock the head into place.
Using the measurement create a template from my old friend poster board.
I use a catalog as cutting board when trimming poster board.
Test fit of the template. Notice the two pencil marks below the template on the rocker panel that mark the left and right location of the fuel hose.
Use the combination square to re-position the fuel hose and check if the poster board template is the right size.
After the test fitting I decided to increase the size of the actual cover plate.
I'll make the cover plate from this steel plate.
It's the left over inspection plate from the rear of my old washing machine. Gone but not forgotten. The inspection plate metal is just the right thickness for this type of application.
Use the jigsaw to cut out the plate. Use my workshop garbage can to support the plate as I cut since it's the right size and better yet the metal shavings won't have to be swept up later.
When using the jigsaw it will sometimes leave behind a sharp cornice of leftover metal. I always use a file to clean off the sharp edge before doing anything else. If not, there will be blood.
Transfer the location of the hole from the template to the cover plate.
Find the center of the circle and mark it with a punch.
The center punch helps keep the hole saw from wandering. Drill out the hole for the fuel hose.
Since the cover plate will be up against the hose, I filed down the edges of the hole till it's smooth enough that I can safely run my fingers along it.
Test fit the cover plate. The ground wire also fits through the fuel hose hole.
Move the hose into position and mark the edges of the cover plate.
Ready to seal up the rocker panel. Use a screw clamp and wrench to attach the fuel hose to the fuel inlet.
Will use sheet metal screws to hold the cover plate to the side of the rocker panel. Start with #8 screws. Can always move up to #10s if needed.
Pre-drill the holes for the screws.
Test fit the plate, screws, hose and fuel tank.
Here's the silicone sealant I've been using.
Place the sealant around the perimeter of the cut out.
Screw the cover plate into place. Use more sealant around the edge of the plate and all around the fuel hose. The more sealant the better. Let the sealant set up.
Doing all this work under the van I found that the fuel tank works as a good head rest.
As usual, I wasn't working alone.