SDS Fuel Pump Module Mount Plate / Modifying the F-14106 Wiring Channel

Modifying the F-14106 Wiring Channel

With the previously recieved approval from Van's to modify the F-14106 Wiring Channel, i pulled out the tin snips:

Fuel Pump Mounting Plate

Similar to the SDS Injector Relay Box mounting plate, I used OnShape to draw up a plate which would interface with the existing fuel pump mounting brackets in the tunnel, and provide a spot for the SDS Fuel pump module to mount. This was sent off to China, and laser cut from 3mm 5052 Aluminium plate. 

The above part has holes for the mouning nutplates - we actaully had the plate cut without these holes, and match drilled the fuel pump module once we got it in a final position. 

An additional 4 nutplates were insalled into the fuel pump brackets - luckily i had already dimpled these. I used some CCR-32 pull rivets to install these nutplates. 

Since the fuel pump module is now in its final location, i was able to template up and make the rigid fuel line from the fuel selector to the inlet of the fuel pump module. I also removed the fuel selector, and final installed the fittings on the forward side, including staking all the screws.

To make the templates, i cut a bit of cardboard to rough size, then added some Blu-Tac in where i estimated the correct locations were. I could then press this on the side of each fuel fitting and get an accurate location of the 2 fittings in relation to each other. This works well when the fittings are in the same plane.

Here you can see the impressions left by the flared fittings. 

I could then extent lines perpendicular ro the face of the fititngs, to give me the bend angle. 

The Van's drawings for the stock Andair filter wanted a bend angle of 24 degrees - my templating came out at 25 degrees. Pretty close.

I then made the bend, and cut the tubes to length.

I had previously worked out you lose 1mm from the length of the tube when making a flare. and the tubes need to be 3mm longer than the face of the flare fitting to fit nicely. 

Tube cut to 3mm longer than the face of each flare fitting.

Carefully deburred.

Fittings on - IN THE RIGHT ORDER!

Correct tube size selected

Tube end alinged with the tang, then tightened.

Some oil added, and the flare gently made.

The completed tube.