The first thing I did was cut the radiator cooling
hoses to length. The input hose is 30”
long and the output hose is 20” long.
There is a short piece of rubber hose left which will be used in a
future step. Next I inserted the springs
into the hoses. That was a chore, but by
holding the end of the spring with a pair of pliers I was able to twist them
into place.
Next I cut the stainless
steel hinges to length to make the 2-halves of the cooler box hinge. Using the hinge pin I fabricated the pin for
the cooler box door. I clamped the hinge
to the cooler box door and then match drilled the hinge per the door hole
layout. I dimpled the door and used the
#40 microstop to countersink the hinge.
I riveted the hinge to the door. Next I dimpled the door for the door
bracket. I used the microstop to
countersink the bracket and then rivet the door and bracket together.
I then clamped the hinge half to the cooler
box face frame and match drilled the hinge.
I removed and deburred the hinge and then riveted the face frame and
hinge half to the lower firewall.
I riveted the upper and lower cooler box ribs
to the face frame and firewall.
I installed the cooler box door and safety
wired the hinge pin to the upper rib.
