SDS - Fuel Block mounting and Injector hoses

The SDS system uses a fuel block which can be mounted in one of two places. The first option is on top of the engine - this necessitates running the fuel supply and return hoses through the baffle. The second is to mount the fuel block on the baffle itself, and this was the method i chose. 

The hardest part was working out where to place it - it needed to be in a spot where the supply and return hoses would not interfere with the engine mount, engine case, or any other items such as the prop governor cable, or the standby generator cooling tubes. It had to be low enuogh to clear the baffle rubbers. It also had to be located in a position which worked with the supplied injector fuel hoses - although, it's always an option to have some more made up locally. I was able to make the supplied hoses work, although a couple are a little tighter than i would like. 

The fuel block came with a nice aluminium drilling template - this was used to match drill to the baffle. The holes in this were then enlarged, and i used this as a doubler. I may end up making a larger doubler to stiffen this part of the baffle (riveted on) - we will see when we run the engine how much movement there is. 

The fuel block was located to ensure both the supply and return hoses would not interfere with anything, and the injector hoses would all reach their injectors ok. 

Thankfully Ross sent me 6 different length hoses so i coucl pick and choose which ones fitted the best. 

The doubler mounting holes were drileld first, then it was attached with temporary nuts. I was then able to drill the holes for the fuel flare fittings to pass through the baffle.

I enlarged the holes in the drill guide to use this as a doubler. I may need to replace this with a larger doubler which is riveted to the baffle, if i find that this ends up having too much movement. 

Loctite 577 was used on all pipe threads.

The holes in the doubler are clearance holes for the straight flare fitting NPT threads. 

All steel lock-nuts were used.

The hoses were seperated from all wiring using some MSD spark plug seperators (if parrallel), or some silicone fuel vacuum hose and zip-ties (if crossing perpendicular).  

In some cases ADEL clamps were more appropriate.