Andair Fuel Pump installation problems

BSwayze · Post by **BSwayze** » Wed May 05, 2010 8:50 pm

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:

http://www.europa.com/~swayze/RV-7A/Fus ... 00502.html

and here:

http://www.europa.com/~swayze/RV-7A/Fus ... 00503.html

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.

hydroguy2 · Post by **hydroguy2** » Wed May 05, 2010 9:03 pm

any chance the cover could straddle over the top of the stiffener ribs?

Post by **bullojm1** » Wed May 05, 2010 9:04 pm

Bruce,

Is there any way you can use a pair of hand seamers to "work" the bend of this plate more inward? It might be worth a shot. If that doesn't work, I definitely wouldn't replace the floor stiffeners. Just remake this out of a flat piece of sheet and rivet on two pieces of 3/4"x3.4" angle to interface to the floor stiffeners. If anything you can make it look better than what came with the kit!

hydroguy2 · Post by **hydroguy2** » Wed May 05, 2010 9:19 pm

Good idea Mike. Just cut the edges off the cover plate and rivet angle pieces in their place.

captain_john · Post by **captain_john** » Wed May 05, 2010 9:20 pm

Bruce,

I had the exact same problem. I had the hum and also installed the andair stuff.

I used my hand seamers to modify the part. It fits much better now. Press on!

CJ

Post by **Spike** » Fri May 07, 2010 12:03 pm

Thats a no sweat problem. Just redo the part if necessary. I would't touch the floor stiffeners.

captain_john · Post by **captain_john** » Fri May 07, 2010 3:35 pm

OH YAH! That is FOR SURE!

Leave the stiffies alone!

Don't mess with structure to accommodate ancillary items.

No doubt, van SHOULD have mentioned using the cover plate as a guide when installing the 2 center stiffies... but they didn't!

Soooo let that be a lesson to you kiddies!

CJ

BSwayze · Post by **BSwayze** » Fri May 07, 2010 4:21 pm

All I can say is, you guys are AWESOME. Thanks for helping keep me on track and avoiding a big sidetrack down the wrong trail. Sometimes when you're upset about something, you can't even think straight. Later on when the solution becomes apparent to you, it's so simple.

I now have a simple, elegant, workable plan, thanks especially to you, Mike, and Brian. I'll post an update and some pics here to show you what I did as soon as I'm finished.

airguy · Post by **airguy** » Mon May 10, 2010 9:29 am

I'm up against the same issue on my 9A (fabbing the fuel/brake lines now) but not to the degree you are having. Mine is livable and I can "make it work", but I would definitely NOT start drilling rivets and try to move the stiffeners at this point - it would be way easier to make a standoff out of angle and refab the cover to fit the angle.

And yes, Van's "should" have you size the distance using the cover when installing those - but what are the odds?

BSwayze · Post by **BSwayze** » Tue May 11, 2010 6:50 pm

Well, I'm very, very happy to report on the solution I came up with and show you the results. I tried the 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 Mike and Brian 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/Fus ... 00503.html

I'll jump forward 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 with the fuel pump and bracket:

And finally, the whole assembly in the fuselage. Everything fits perfectly!

Now 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 like this that doesn't fit right, whether or not you have the Andair fuel pump. 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!

hydroguy2 · Post by **hydroguy2** » Tue May 11, 2010 7:08 pm

looking good Bruce. All that worrying for nothing. good job

Post by **Spike** » Wed May 12, 2010 1:48 pm

That looks great!

Bob Barrett · Post by **Bob Barrett** » Wed May 12, 2010 7:22 pm

It looks great and I am really amazed at how good you are at painting the interior. Keep on pounding rivets and bolting things together.

BSwayze · Post by **BSwayze** » Wed May 12, 2010 10:18 pm

Thank you, Spike and Bob,

I wanna be like Brian and paint my own plane when she's all grown up!

Bob Barrett · Post by **Bob Barrett** » Thu May 13, 2010 9:03 am

When building your own airplane, know your limitations! I have painted wrecked cars that I repaired. However when I got an almost new 88 Dodge Carvan in January 1989 with 5600 miles on it I hired a painter. When I was close to ready to paint my airplane, my wife said hire it done so it looks decent! She had wise words! Now my wing tips, wheel paints are being painted at a body shop. It looked for a while like I might have to paint them myself but my paint gone is gone.

I wonder if my wife threw it in the garbage?