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Marlins Web Site
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Date: 2-28-2009
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Number of Hours: 18.00
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Manual Reference: Section 8; OP-21
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Brief Description: Installing High Pressure Electric Fuel Pump Cover
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I ordered an "Aerflow Performance" electric boost pump for my IO-360 Fuel Injected Lycoming Engine. I was a little surprised at what came in the kit and all the work you have to do to modify the existing center console. The kit comes with a fuel pump, a relief valve, a check valve, some aluminum sheet metal with a couple bends, and 5 feet of aluminum tubing. The instructions tell you to modify your existing center consol, cutting parts of it off to match a new mounting plate, build the new fuel cover, and then assemble the pump. The first two pictures below are the new cover...simple enough, but then when it comes to modifying the existing center console (the parts below and behind the new cover), that's when things got a little complicated. In the third picture below, the big piece (front lower left) was the center console I built months ago. The new instructions told me to create a new rectangular cut-out and match it to the new valve mouting plate (3rd picture, lower right). I chose to use my band saw to make the cut...bad choice because my band saw blade is getting dull. The aluminum is very thin, the band saw grabbed the metal and and tore the flange on the left. Needless to say it was completely destroyed. You are probably looking at the picture and saying, it looks OK to me and you are right...this version now looks OK to me too. After ordering a new center console, bending all the vent blades, removing and reinstalling 12 nuplates and making the modifications using metal shears, it's much better. I also decided to paint my interior exposed metal parts using a hammered aluminum paint. You never really know what its going to look like until its dry, but I like it. The next few picures will show the new paint.
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Fabricating Fuel Valve Cover
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Close up picture Fuel Valve cover
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Modified Center Console
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