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Date:  2-28-2008
Number of Hours:  1.00
Manual Reference:  6W7B 7
Brief Description:  Mock up & test new fuel pump channel

As noted on 2/27/08, my original channel design was fatally flawed--not rigid enough. So I set out to design a new channel. Unfortunately, the only 6061-T6 aluminum I have is .025" thick, so I could not easily implement the previous design in a thicker, stiffer, sheet.

I decided to try a design that was more like Motis' original design--a simple U-channel riveted to the nose rib attachment L-angles. However, I will need to mount it between ribs 2 & 3, so that will require that I mount it higher than the line of the finger screen. But, the specs on the Facet 40105 fuel pump are that it is self priming to 18", so that should not cause an operational problem.

Also, in view of the problems with the 1st design, I wanted to test out the rigidity of the new design. I cut the supporting arms off of the previous channel to make a somewhat shortened version of a simple U-channel. The arms of the U-channel were 35-mm long. I drilled 3 rivet holes in each arm of the U and into pieces of 1x2. Then I clecoed the channel to the 1x2's. Next I clecoed on the original L-angle reinforcements to the test assembly and bolted on the fuel pump. Finally, I clamped the 1x2's to the table top. See Figs. 1 & 2. The underside of the test assembly is shown in Fig. 3.

Once it was all together, I pushed and pulled on the pump and found that the channel was quite rigid. I think that the new design will work very well. It will be even more rigid when the clecoes are replaced by rivets. When I build the actual new channels, they will need to be 157-mm wide rather than the 132-mm width of the test assembly. Hopefully, the additional width will not significantly weaken the design.

I will probably also design the new channel so that it engages 4 rather than 3 nose rib rivets.
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Test set up for channel_1

Test set up for channel_1

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Test set up for channel_2

Test set up for channel_2

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Bottom of channel

Bottom of channel

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