Left wing: landing light cover and fuel level sender

TLDR

• Fuel sender and a few smal parts for left tank
• Tried to fit left landing light lens

Fuel tank parts

I wanted to front load some work before sealing the left tank.

Fuel level sender

I chose to first finish the fuel level sender. I took apart the fuel level sender from its original assembly. Then installed it to the Sling sender cover. I needed to slightly enlarge a few holes to make the o-ring fit. But overall it’s not too bad.

I took some extra time to measure the ohm level to make sure I installed it at the correct orientation, since the instruction showed only the right sender. So I needed to mirror it to keep the ohm reading correct.

I smeared a ton of pro-seal on the cover. Then I put it aside to cure.

Fuel level sender with proseal

Another shot

Back shot

AN fittings

There is an AN4 fitting on the fuel overflow port, and an AN6 for the fuel inlet. I tried to fit them on the rib with washers. I didn’t tighten them yet. I want to hold off pro-sealing until I match drill everything. Once all the match drilling shavings are cleaned up I will pro-seal them both.

Fuel inlet fitting dry-fit, not torqued yet

Landing light cover

Cover and doubler_

This is the strange part. I started by clecoing the lens and doubler together. It’s a good fit.

However, when I try to fit the lens to the wing skin it does not fit at all.

I can barely cleco the top and bottom row of holes to the skin, but the sides are completely out of whack. The holes are not even close to match.

Sides do not match

From the picture above, the holes on the lens and the skin are completely out of alignment. No amount of countersinking or match drilling will help… I think Sling sent me wrong parts or something. I will need to drill new holes and probably close the old ones with some JB weld.

Since this will be in a tight space, I can imagine this will be a long job.