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  #1  
Old 05-05-2010, 08:42 PM
BSwayze's Avatar
BSwayze BSwayze is offline
 
Join Date: Jul 2007
Location: Molalla, Oregon
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Default Andair Fuel Pump installation problems

The installation of my Andair Fuel pump assembly is giving me fits. After fiddling and working on this for way too long, I reached the big moment to start putting it all together only to find out my center cover, F-782C, doesn't fit between the two center floor stiffener ribs when I have the brackets and plate attached. I have posted a more thorough discussion and pictures on my web log here:

May 2, 2010 entry

and here:

May 3, 2010 entry

The problem, as I see it, is that my floor stiffeners are too close together causing my center F-782C cover to curve and warp. It's even worse when I try to install the pump assembly and bracket. Back about a year ago when I drilled them to the bottom floor skin, I drew a centerline down each stiffener and drilled them to the floor. How I wish I had known how critical the separation distance is between these floor stiffeners. A short note in the plans on Vans part would have saved me this mess. Look at these pictures, and you'll see what I'm up against:



I put a straightedge across it, shown below, to show just how bad it is.



I don't know what I'm going to do. I'm considering drilling out several dozen rivets and removing these floor stiffeners, and replacing them with new ones that are separated a bit more. It's a job I shudder to seriously consider, but what other option do I have? Has anyone else run into this? What did you do?

Is anyone else installing an andair system, that can share their experiences?

Thank you for any comments or help.
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  #2  
Old 05-05-2010, 08:57 PM
SteveHRV7 SteveHRV7 is offline
 
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Location: Okemos, Michigan
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Default

Bruce,
I also noticed that the brackets were a bit wide when I first made them. My F-782C cover fit fine by itself but when I added the brackets it was too long. I believe I heavily rounded the corners of the brackets so the nestled into the cover without widening it too much.
Steve
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  #3  
Old 05-05-2010, 09:13 PM
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miyu1975 miyu1975 is offline
 
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Location: Indianapolis, IN
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Default

I have the same problem with mine...but I haven't dealt with it yet. One option I considered is to not put both the flanges of the of center piece outside of the stiffners. You could put one flange on the inside and one on the outside. You would have to redrill your platenuts accordingly. In the end, especially with carpet...no one will know but you.
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  #4  
Old 05-05-2010, 10:17 PM
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schristo@mac.com schristo@mac.com is offline
 
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Location: WA
Posts: 988
Default ditch the cross braces...

i purchased my pump before andair had worked out a filter and attachment bracket and per recommendation from andy am using gasolators in each wing root as filters as he installed the pump in his rv. for mounting, i used a backing plate under the cover along with nutplates to anchor the pump and controller keeping the passthrough clear for the fuel, antenna, wiring, or brake lines for tri-gear models.

here is a link to my entry on mounting the fuel pump with a few photos for reference:
http://www.schristo.com/RV7/Log/Entr..._mounting.html

one note on carpet... the center section is not insulated with sound batting (from classic aero designs, likely others as well) so that the finished carpet floor is the same height all the way across. i added 3/8 of sound matting in the tunnel... not sure if it will make a difference but it is right under the exhaust...

here is a link to my entry showing the sound batting, wiring, piping, etc.
http://www.schristo.com/RV7/Log/Entr...re_lacing.html
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  #5  
Old 05-05-2010, 10:18 PM
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Bruce Bruce is offline
 
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Default Z Brackets

I used Z brackets cut them in half and then mounted them
on the floor rail and the fuel pump bottom sits on top with the
screws going in from the top.
Much better solution to this problem.
On my web somewhere.

Hope this helps.

Boomer
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  #6  
Old 05-06-2010, 06:59 AM
Bruce9A Bruce9A is offline
 
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Default Andair fuel pump mounting

Bruce,
I didn't like the method that Andair suggested (it seems like it would interfere with running brake lines under the pump, and I couldn't get the pieces of angle to fit well under the Van's cover), so I ordered some 0.063 sheet and some 3/4" angle (same type as the floor stiffeners) from Spruce and made my own 782C. The angle pieces fit inside of the floor stiffeners, and they will be riveted to a cover plate made from the sheet. Attachment of the new cover to the floor stiffeners is just like the attachment of the Van's cover. I think the 0.063 sheet is heavy enough to support the pump, although I made a couple of stiffeners (3/4" angle with one of the sides trimmed down to 1/4" to allow clearance for brake lines) that will go on the underside of the cover where the mounting bolts for the pump come through. I'm still using about half of the Van's cover (from the pump forward), but there's no reason that a home-built cover couldn't go all the way to the firewall. I fabricated the parts about a week ago, so nothing has been permanently installed or flight tested, but I think it should work fine. With shipping, I think it all cost about 30 bucks, and I have a big piece of the 2'x2' 0.063 sheet left over for other projects.

-Bruce
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  #7  
Old 05-06-2010, 08:35 AM
389JM 389JM is offline
 
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Location: medford, oregon
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Default Andair Pump

Bruce,

I sent you an email.

Jim Haran
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  #8  
Old 05-11-2010, 07:59 PM
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BSwayze BSwayze is offline
 
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Default

Well, I'm very, very happy to report on the solution I came up with and show you the results. I tried hand seamers, but the problem was too severe to make this work. I also tried putting the flanges of the cover on the outside of the ribs. That didn't work either. So I ended up doing as some have suggested. I cut the flanges off the F-782C cover and riveted new ones in place.

I also decided to ditch the angle crossbeams shown in Andair's plans in favor of a stiffener plate. By the time you cut the angles to allow your brake lines and electrical lines, antenna lines, and so on to pass through underneath, there won't be much left of them anyway.

I have lots of pictures and details of how I did it in my web log starting here:

http://www.europa.com/~swayze/RV-7A/.../20100503.html

I'll give you the short version here and show you the results. It turned out real nice, I think. Here's the center cover before I cut off the flanges, with the new angle pieces and stiffener plate I used:



Here it is all riveted together and a shot of JetFlex to finish it up:



Trial fitting on the bench with the fuel pump and bracket:



And finally, the assembly in the fuselage. Everything now fits perfectly.



Now after messing around with this for way too long, I can finally get on with putting in the fuel lines, brake lines, and get this whole plumbing project wrapped up.



Incidentally, I think this is a good option for anyone who has a cover that doesn't fit right, whether or not you have the Andair fuel pump. I'm real happy with how nice this turned out. The cover is now flat as a pancake, fits snug as a bug, and looks really nice.

Thank you, gentlemen, for your hints and your help!
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  #9  
Old 05-12-2010, 12:25 PM
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RV7Factory RV7Factory is offline
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Default

Quote:
Originally Posted by BSwayze View Post
I also decided to ditch the angle crossbeams shown in Andair's plans in favor of a stiffener plate. By the time you cut the angles to allow your brake lines and electrical lines, antenna lines, and so on to pass through underneath, there won't be much left of them anyway.
I was all set to start installing the angles, even ordered some supplies from ACS, but based on your statement above I may have to re-think my plan. Thanks for the info.
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  #10  
Old 05-12-2010, 12:38 PM
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BSwayze BSwayze is offline
 
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Location: Molalla, Oregon
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Quote:
Originally Posted by RV7Factory View Post
I was all set to start installing the angles, even ordered some supplies from ACS, but based on your statement above I may have to re-think my plan. Thanks for the info.
You're welcome, Brad!

I have no regrets about going this route. My EAA technical counselor, Dan Benua, had also noted previously on a visit here that those 1/8" thick crossbeams were overkill and that I could consider doing something different. Check my web pages for lots more details and more pictures of how I did this.

I have followed your progress for a long time, Brad. Your site has been a huge inspiration and help to me. Especially when I was building my wings. You have a reputation for doing excellent work and I'm sure you'll make a good decision here as well. I'm anxious to see what you decide to do.
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