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Rob's REBVAIR Project
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Date:  5-21-2010
Number of Hours:  20.00
Manual Reference:  Chapter 12
Brief Description:  Fuel Line (part 2)

Fast forward two weeks: Well I wasn't entirely satisfied with the bends I created in the footwells in part 1. There were flat spots from using the "spring" bender (the good tube bender wouldn't fit into this corner) and while they did not meet the 'official' rejection criteria of 75% of the OD of the tube (Advisory Circular, chapter 9) I reconsidered what I was trying to accomplish:

Priority 1 was to keep the tubing in the corner wraps. Priority #2 was to not have concealed unions, and priority #3 was to limit unions to reduce potential for leaks. My EAA chapter Technical Advisor Joe assured me that he had seen many AN unions used without issue.

So I came to a compromise: Having one straight union around the rear window area would allow easy maintenance if required, and the shorter length (8') would allow the use of the good tubing bender to execute nice bends in the foot well, eliminating a set of right-angle unions as the fuel lines exit the corner wrap area. You can see the final result in image 1 through 3. As mentioned, both lines join in the center at a "T" before heading to the firewall through a single line (not shown here).

By the way, I should mention that I tried making flared fittings with a 'cheapo' flaring tool from Summit racing. When I questioned the results, my Technical Advisor told me to stop screwing around and get a proper flaring tool. He recommended the Parker-Hannefin Rolo-flair and I was fortunate to get one for $80 on sale at aircraft-tool.com. There is absolutely no comparison. I used it to complete the necessary fuel line fitting/adjusting before closing the floor up. Four flares (and several hours of riveting later) the final product is very gratifying.
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right side fuel routing

right side fuel routing

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left side fuel routing

left side fuel routing

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foot well

foot well

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