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My Airplane Projects
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Date: 10-2-2009
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Number of Hours: 7.00
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Manual Reference: 28-05
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Brief Description: Continued work on fuel system - some problems.
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Assembled and mounted fuel valve. Practiced making bends in 3/8 tubing using the old oil tank scrap. Made up the tank-to-pump pipe with no real problems. Corners are not perfectly square but the gas flowing through won't know the difference. Made up the pump-to-valve piece and installed OK. Began work on the valve to flow sensor section, and that's where the day began to go down hill. The previously installed mounting bracket for the flow sensor was set up for the wrong sensor. The plans were for one sensor, but the other sensor was sent with the kit. Got Carolyn to help me roll the fuselage up on the side so I could drill out the rivets holding the bracket to the bottom skin. Removed the bracket, but could find no correct size 1/4" nutplates. Called tech support later, and Gus says there should be some of the right size here somewhere. I'll look tomorrow. Also need to pick up some AD4-17A bolts to mount the sensor, since these didn't come in the kit either.
Moved on to work on the return lines. Started with the tank-to-bulkhead piece. Mis-read the instructions and put the first bend in the wrong place. Tried to salvage that by swapping ends and using that end for the bulkhead end. That worked after some careful re-bending, but now working backwards to the instructions I put the bends in the wrong places where the return line has to follow and be clamped to the feed line. Gave up on that piece in disgust, and moved on to the big long stretch between the bulkhead and the firewall. Complex bends near the firewall are tricky, but I think I have a configuration that will work. Still have to cut and connect the aft end.
Carefully straightened the aforementioned piece with the bends in the wrong places. Asked Gus at tech support if it would be acceptable to rebend this peice, and he said yes, as long as it doesn't crack. He also said I could just pick up some new aluminum tubing at home depot.
I now have the fuselage up on its side, tied to the ceiling for safety. Reconfigured workbenches.
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Practice bends with scrap.
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Fuel shutoff assembled & mounted.
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