Fuel Tank Door

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With the front turtle deck completed it was time to add the fuel tank for.  I cut the deck skin of where the filter neck is located and used the flush cut router bit around the edges.

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Fuel tank door opening

The RS-505 aluminum sheet was carefully cut and bent to fit into the opening so the outside was flush with the deck skin.

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Bend and cut RS-505 to inside the opening

The corners of the skin were left round from the router so I also rounded the edges of the door. The top of the door is notched so the hinge is recessed into the door. This eliminated sharp edges and looks attractive.

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Hinge recessed into top of door

After driving to the hardware store and not finding a suitable latch I decided to fabricate one myself. Using a piece of RS-700 I bent a spring latch.

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RS-700 spring latch

This securely holds the door closed and is easy to open too.

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Latch attached with two #6 x 5/8" stainless steel wood screws

I put a scrap piece of 1/16″ plywood along the bottom of the door so the latch dors not push the door in too far.

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1/16" plywood to prevent door from closing too far

The final result looks great, door is flush with the skin and follows the contour nearly perfectly.

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Door matches deck skin nearly perfect

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