STEP 1 – Boat Stand
Construct a boat cradle using 3/4-inch ID PVC pipe with 1 8-inch long horizontal bars wrapped
in cushioning tape (see Pic. #9). This cradle will be useful in the transporting and general
operation of the boat, and if built early would assist in the initial assembly of the boat.
STEP 2 - Fuel Tank Assembiy
1. Open the 2-oz. fuel tank package (5a) and discard the two brass tubes, two 6-inch nylon
Tubes and the metal ties (very sharp). Open the 24-oz. fuel tank package (5b) and discard
one of the 1/8 brass tubes, two 6-inch nylon tubes, metal ties, and the black gas stopper.
2. 24-oz. tank-. Make a fuel vent tube by using an Allen wrench and finger-bend 2 inches of the
1/8-inch brass tube (from 5b pkg.) to about a 120-degree hook shape as shown in Picture #1.
This curved end must fit up in the bubble of the 24-oz fuel tank; re-bend the tube if necessary.
The remaining 1-1/2 inch of tube can extend from the tank neck.
3. 24-oz tank: Make a fuel pick-up tube using the 5/32-inch brass tube (5e). Heat 3 inches
Of one end with the propane torch and use an Allen wrench to form a 45-degree bend (see
Pic. #1). The curved end must lay flat in the tank bottom and face aft and to the left corner.
Optionally, cut the tube tip at a 90-degree angle to maximize fuel pick-up. This time, allow a
3/4-inch extension above the tank neck. Cool the heated tube in water and cut-off & save the
excess tube. Deburr this cut(s) and all future brass tube cuts.
.
4. 2-oz. tank- Make two fuel tubes using the excess 5/32 brass tube. Repeat above Step 1.3 but
cut & bend two 3-inch lengths (see Pic. #1). Note that the fuel-out tube (to carburetor) must lay
flat in the rear left corner of this tank and the fuel-in tube must fit up in the bubble, Extend both
tubes 3/4-inch above the tank neck- discard the remaining 5/32 tube.
5. Tank caps: Remove the cap parts from the 5a and 5b pkgs. (i.e., small nylon caps, rubber
stoppers, larger outer caps and 2 #6 tap screws). Enlarge the hole size in the nylon caps for
the 2-oz tank to 5/32 for both holes (to accept the fuel-in and fuel-out tubes). For the 24-oz
tank, enlarge the left-side cap hole to 5/32 and the other hole to 1/8 for the vent tube. Check
the tank neck & cap lids for a smooth surface; remove any mold imperfections.
6. Refer to Picture #1 and route the fuel and vent brass tubes through the tank caps as shown
(i.e., insert the tubes threw the aligned holes in the smaller cap, the rubber stopper, the outside
cap, and then compress tightly together.) Assemble the caps for both tanks. At this time,
finger-bend the l/8 tube extension (24-oz. tank cap) slightly toward the stern.
7. Firmly insert the cap assemblies onto the respective fuel tanks (cap with 1/8-inch brass
Tube goes on the 24-oz tank) with the brass tubes properly positioned. (If tube adjusting
Is needed, use pliers and lightly twist until the respective tube is positioned flat in the bottom
of the tank or in the tank bubble as previously specified.) When all tubes are in place, add
the #6 tap screws (step 1.6) to the cap centers to expand & lock-in the caps.
8. Refer to Pic. #2 and center drill 1/16 holes in the four wood-reinforcement points on the fuel
tank holding tray (3b). Screw in four of the #6 brass hooks (5f). Place the fuel
Tanks in the holding tray and secure with the double 6-inch ty wraps (5g) per Pic. #2.
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