So while I wait for an order from Vans to come in (with the tank sealant, otherwise known as “black death”), I decided to grab a project that would feel and look good. The ER tank access panels.

Each access panel is actually a piece of the leading edge that is cut down to fit between the two tanks. I’m using two join plates (parts that normally connect the outboard part of the tank and the inboard part of the leading edge). The inboard side of the access plate is easy, it’s already predrilled for rivets and screws to connect with the main tank. But I have to fabricate the outboard join plate, which I will permanently attach to the ER tank, and provide screw holes and nutplates for the access plate.

After getting some nutplates attached to the outboard join plate, I snagged this picture to help me count rivets.

Because there are holes in the join plate, but not in the access panel, I used an old trick to copy the hole pattern. Blue tape to the rescue!

After drilling #40 pilot holes, then enlarging to #19 for the #8 dimple, I finished the access plate and set in kind of in place so you could get the idea.

I grabbed the left ER tank and put it in place. What you can’t see very well is that all the screw holes line up. Once I put screws in this baby it’s going to look great!

This shot is so you can see the inboard join plate attached to the access panel and the outboard join plate attached (well, clecoed) to the left ER tank. Without the clecos there, it slips right in and can be screwed/unscrewed easily.

I think this is just another victory shot. Oh wait, counting rivets.

Later tonight, I had another hour to spare, so I decided to come knock out the right tank’s access panel too.

Then, once finished, I set this in place just to prove it to you.

3.5 hours. 58 rivets each side, so 116 total.