Aerosport Hints

Hints for installing Aerosport Interior Products

Front side panels

• The recessed map pockets / cup holders occupy the space between the outer skin and the inside wall thus interfering with thicker battery cables or AC hoses that might be run across this section.

Overhead Console

• Installation Video
• Rear end bulk head interface, see this FB Thread

Armrest with Throttle Quadrant

• Installation Instructions
• Installation Video
• Good tools for trimming carbon fiber:
  • Pencil grinder
  • Dremel Cutting / Shaping Wheel
• Hints
  • Don't dimple #8 the tunnel cover holes in the area where the armrest will sit.
  • If you have the Aerosport panel with a center console, the fore/aft position is determined by mating the arm rest with the center console.
  • If you have a stock panel, the fore/aft position is determined by where you want the fuel valve handle to sit. Not too close behind the throttle quadrant so you can reach it and not too for forward as the throttle quadrant may be too far aft.
    Steps:
    • Make a roughly 2.5 x 4.5 inch doubler for the Andair fuel valve from 64 to 80/1000 inch thick aluminum.
    • Put a 30-31 mm hole in the middle.
    • Clamp the doubler below the Vans fuel valve bracket with the center hole aligned (later to be mounted on top of the bracket).
    • Pick 6 outer locations and drill #30 holes with good edge distance for 1/8th rivets to secure the doubler to the Van's bracket.
      
      File:Screen Shot 2023-07-18 at 6.44.55 AM.png
    • Trim the Van's fuel valve bracket so the Andair valve fits onto the doubler.
    • Change the order and put the doubler on top of the Van's bracket and check clearance to the Andair valve.
    • Mount the valve and insert the extension tube
    • Upsize the fuel valve hole in the tunnel cover so the extension fits easily through it.
    • Secure the tunnel cover to the tunnel with 4 bolts.
      .
    • Mark the extension where it comes out of the cover.
    • Mount the Fuel selector at the desired spot into the armrest and stick the extension into it.
    • Clamp the tunnel cover into the armrest with the extension centered in the cover hole and the bottom edges aligning (there might be interference at the friction lock recess - trim back carefully).
      
    • Temporarily mark and measure how much of the extension is needed from the tunnel cover to the fuel selector.
    • Add a 1/4 inch of reserve to the measurement and add it to the first marked position where the extension came out of the cover and trim the extension.
    • Assemble everything, find the sweet spot for the extension to not be under tension and mark the armrest mounting holes using a hole finder.