This evening I installed the Molex connector on the trim wires at the rear of the fuselage. I started by cutting off the spade connectors and stripping the ends of the wires. Using the Molex wire crimper I attached the male pins to the wires. These pins are extremely small, especially when you have big hands and fingers. I worked really hard to get the pins to lock into the connector. I ended up getting a magnifying glass so I could look inside of the connector body. I was finally able to get the pins to lock in place by bending out the little tabs on the sides of the pins. I am a little concerned because when I was finished and put the connectors together they went together really easily. I was expecting to feel a little more resistance, but I guess with such small connectors there would not be a lot of resistance in the assembly process. I will have to test the wires out in the spring to make sure the connections are good.
I also marked the turtle deck skin so I can open the hole for the gas cap a little larger. I will do that sometime soon.
Next I started the retro-fit of the fuel tank. Van's issued a Service Bulletin concerning the fuel tank. Because a fuel tank was damaged during a hard landing, they have redesigned the attachment of the tank to the center cross channel. They have added 2-clip angles which are riveted to the tank and the forward support bar. The tank is then installed with frangible head bolts. That means the head of the bolt will come off before the tank integrity is compromised. I started by removing the sender unit support plate. I removed the screws holding the plate in place. I sharpened the edge of a putty knife so I could cut through the Pro-Seal between the tank skin and the support plate. It wasn't too hard to get them separated.
I drilled out the rivets holding the nutplates to the mounting bar and also drilled out 3-rivets that interfere with the installation of the new attachment angles. I then drilled and clecoed the attachment angles to the tank and the mounting bar.
I drilled and countersunk a new hole in the mounting bar for the extra hole in the attachment clip. I also prepped and primed the new clip angles so they are ready for installation.
While the tank is open I decided to install an additional clip inside of the tank to secure the fuel return line. It was pretty simple to make a new clip then drill a hole in line with the other clip rivets and clecoe the clip in place. I will install the clip when I mix up some Pro-Seal.
