Thursday, November 13, 2008

Directions for installing the fuel filler

1. Throw away the straight 2" rubber hose that you received with the kit. It is intended for the roadster and has no place on your coupe.

2. Buy the LeMans cap spacer from Mike Everson. You need it to keep the LeMans cap from hitting the body when it opens.

3. Buy NAPA part NBH 1046, 2" fuel filler hose with 45 degree bend.

4. Cut the fuel filler hard pipe. Leave most of the straight portion after the 90 degree bend on the lower piece. If you followed the manual and cut near the middle of this straight portion, you should have just barely enough straight pipe to make it work. The upper part needs to be cut down to just the last straight bit before the bend. Try to cut just behind the "bulkhead" in the tube with the spring door.

5. If you're a master craftsman like Russ, cut the tack welds on the fuel filler flange and reweld it closer to the end of the pipe. This not only looks cool but will save you the frustration of dropping the little white spacers about 10 times as you're trying to align the flange with the body and get the nuts on the screws. (Personally I didn't do this, because the thought of welding on thin pipe terrifies me.)

6. Position the fuel filler pipe in the hole from above. Mark and drill the body for the screws.

7. Get some #10 machine screws, washers, and nuts to replace the sheet metal screws or whatever they are in the kit. I just don't trust anything threaded into fiberglass.

8. Position the cap spacer on the body. Mark and drill the body for the screws. Slide the screws in to hold the spacer in position. From underneath, mark the filler flange screw holes on the spacer.

9. Drill recesses in the spacer for the filler flange screws. Don't go all the way through, but make sure they're large enough to contain the entire screw heads.

10. Screw the LeMans cap tightly onto its mounting flange. Keeping the spacer aligned with the screw holes, position the cap in the desired orientation over the spacer. Make registration marks on the spacer and the mounting flange.

11. Remove the cap from the mounting flange. Using the registration marks, mark the flange. Drill and countersink the flange.

12. Lubricate the filler pipe sections with vaseline to make the fitting much easier.

13. Cut down the hose to fit. I did it by cutting a little, trial fitting, cutting a bit more, etc.

14. Slide the hose clamps over the hose but do not tighten. You need everything sliding freely to geta the best alignment. Also, put the collar thingy on the lower pipe section.

15. Install the pipe/hose assembly and mount the flange to the body. This is where you get to drop those little white spacers over and over again. You can also drop the nylocks. They bounce and roll really well. (They're 10-32 thread, in case you've discovered just how well they bounce and roll.) Remember to install the ground wire on one of these screws. BTW, you could cut at least 1/4" off these screws to save yourself some work. 32 thread, so that's 8 full turns.

16. Tighten the band clamps and install the collar thingy. The bolt for the collar is metric something-er-other fine thread, if you've misplaced it like me.

17. Install the spacer and flange. Be sure the flange is in the same position as when you marked it.

18. Install the LeMans cap. It should tighten to just the right orientation.

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