Fabricating the fuel pump top cover - 2 hours

 Today I need to fabricate the top cover of the fuel pump doghouse. This will basically be a c-channel shape that I will eventually shape into the final cover. To make the initial cutout. I took some measurements of the original stock cover and worked my way from there. I cut a long rectangle out of 0.020" material and then started marking out my flanges. 

The first 90deg bend is fairly straight forward. Once the flange length is set, clamp the oak bending guide, start the bend by hand, and then finish with the rubber mallet. 

 

The next part is trickier. Get the other bend the right distance apart. This is where having the stock cover is super helpful as I can use it as an exact guide. After the opposite flange is bent...I checked it against the stock cover. I'm very happy with it.

Now I am ready to make the flange bend at the aft most end of the cover. Same process....

 

With that done...I am now able to place the cover on top of the fuel pump and establish the final height of the cover. I placed spacers on the top of the pump, placed the cover on, centered it and them drilled with 3/32" holes.

Started the custom fuel pump cover - 2.5 hours

 With the FlyEFII fuel pump and the Aerolab Gascolator I just won't be able to fit everything under the stock doghouse cover. I will need to make my own custom cover. I order to do this, I'll use the stock cover that I have as a guide and make a longer (shallower) version. 

 

I cut the forward fuel access hole out in the reinforcing plate yesterday. I can now get clamps in to hold everything in the right spot. I could then start sketching out all of the lines to determine the rough dimensions of the cover. 

First, I need to make the sides of the fuel pump cover. I choose to use the same 0.020" material as the stock cover. I basically need to cut out a long rectangle and bend one edge with a 90deg flange. 

I clamped the piece to a table and then using a piece of oak with a 1/8" radius, I began the 90 degree bend for the flange. The initial bend is done by hand, with the final process being a rubber mallet. I made both the left and right side covers this way.

 

 

 

Reinforcing the fuel pump platform - 7 hours

 Immediately it becomes apparent that the F-782C tunnel cover is not going to support the fuel pump adequately.

So I will need to reinforce the mounting to allow a more sturdy installation. Since the fuel lines are all hard lines, any excessive movement is sure to invite leaks. I began to think about how I was going to do this, lots of builders have tried various methods. I settled on keeping it easy. My plan is to support the platform with 0.063" baseplate and use 3/4"x3/4x0.063"angle. Here is a mock up to help me sort out the fit and dimensions.

 I started out by cutting the 0.063" plate to the correct size. Then I used a file and slowly worked a radius edge on the plate.

  Next, I rounded the angles with a router and a 1/8" radius bit. This makes for a really great fit with the tunnel cover.

With that done. The pieces are now ready to be fitted and drilled to the center tunnel cover. 

Preliminary installaiton of control sticks and mock-up - 3 hours

 Not feeling that I want to get too in-depth on the build today, I decided to mock-up/fit the front panel area. I've fit the pieces before and things seem very tight with the F-7105 sub-panels. Everything else is spot on so I think it will be just a matter of tightening up the radius of the mounting flanges. Easy enough to do, just a matter of working at it.  As well I like pulling the project out on the driveway when the weather is good like it has been, and it looks great with the front panel on. 

I'm at a point where I can install the control stick assembly. This part can be a little tricky from other build logs and sure enough getting the WD-610 control column slipped into position isn't the easiest, however it wasn't horrible.  What is horrible is getting the AN960-10 washers fitted on the control column mounts. That is horrible and not easy to do. Using a combination of a small film of grease to get the stack of washers to stick together and some safety wire bent to hold the washers...I could get them slipped into position. 

 

For now I just temporary installed the left and right control sticks and the F-665 pushrod for looks, but I will need to remove those and finish those items properly at a later date (Prime the pushrod, drill the safety bolt in the right stick, torque everything).

Modifying the center tunnel for the fuel pump - 6 hours

Time to get to work on opening up the center tunnel for the fuel line that exits the fuel pump. I started out by drawing all sorts of reference lines.

 

Now that I have the hole for the fuel line decided, I also have the line where I want to split the center tunnel into two. This will allow the fuel pump to remain in place if I ever need to get into the forward portion of the center tunnel. I need to drill the mounting screw holes accordingly.

The first cut dividing the tunnel cover in two is made.

I am now able to cut the opening for the fuel line.

 

Completed the right fuel vent line - 4 hours

 Well a decent day of building hours wise. but not a whole lot of forward progress to show for it. I managed to complete the right fuel vent line. Took me a couple tries for the right side still. Having all of the sample bends and the left fuel vent line done is a great template for getting the right side done. 

Here is the left side for comparison.

Completed the left fuel vent line - 3 hours

Well it took some work but I managed to complete the left fuel vent line. I was able to use all of the templates that I made previously as a guide.