Aerosport Hints

Hints for installing Aerosport Interior Products

Panel

• Ed's 28 video series on the panel install. Video 1

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.

Rear side panels

• Ed's rear side panel install

Overhead Console

• Aerosport Installation Video
• Ed's Installation Video
• Rear end bulk head interface, see this FB Thread 2/2024
• FB Thread 11/2023
• FB Thread on adhesive 4/2024

Carpet

• FB Post on what to do with rear crotch strap.
• FB Post on carpet / arm rest overlap

Armrest with Throttle Quadrant

• Installation Instructions
• Installation Video
• FB thread on cable routing
• Christopher's build log on cable routing
• See also SECTION_FF3:_CONTROL_CABLES
• Good tools for trimming carbon fiber:
  • Pencil grinder
  • Dremel Cutting / Shaping Wheel
• Hints
  • Don't dimple #8 the tunnel cover side holes in the area where the armrest will sit.
  • The friction lock hole in the carbon fiber on the side needs to be large enough for the black tensioner stem to fit through and sit against the throttle quadrant, not pinch the carbon fiber.
  • Consider adding washers to the throttle handle bolt on both sides as the machined part is very thin just around the holes (Holes were made with a drill bit rather than with a router bit).
  • The 4 steel screws that hold the bottom mounting angles on the sides are not corrosion protected and don't harmonize with aluminum. Consider replacing them with stainless ones.
  • The position of the handle locks in on the top (selector side), not at the valve. It is absolutely necessary to properly align the valve and the selector assembly, otherwise the paths in the valve are not guaranteed. You can switch between left and right just by turning the selector but you need to pull the lock pin between right and off.
  • Please note that the individual ports of the Andair fuel valve need to be secured with 4 screws each that get peened. Andair may ship some ports only temporarily placed without any screws. They are in the hardware bag that comes with the valve.
  • 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. The general order is shown in the instructional video.
  • 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 for placing the armrest with a stock panel:
    • Make a roughly 2.5 x 4.5 inch doubler for the Andair fuel valve from 63 to 80/1000 inch thick aluminum (e.g. from Spruce).
    • Put a 30 mm hole in the middle with a step drill bit (1 1/4 inch). Note: Mark the hole's circumference so you notice when the step drill bit starts wandering off your desired center. Best to do it in a drill press with the doubler strapped down.
    • 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.
      
      First rough trim back of the Van's fuel valve bracket. Note: the doubler will later sit on top.
      
    • Trim the Van's fuel valve bracket so the Andair valve fits onto the doubler. Note that the tunnel walls may shift inwards without the bracket in place. You might have to spread them a bit to cleco your doubler plate in place lateron.
    • 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. A hand nibbler can clear away the uneven original shape so you can finish up with a step drill bit.
    • 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. Note: Mark the hole's circumference on painter's tape so you notice when the step drill bit starts wandering off your desired center.
    • 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. Check the length of the extension. It should have a tiny bit of slack up and down. Trim it a bit if under tension.
      
      Test fit the placement with the extension in place.
    • Drill a 7/64 hole for the slotted spring pin through the valve end of the extension using the two holes of the valve fitting as a guide. Insert the pin with a hammer to secure the extension to the valve.