Hints for installing TS Flightline hoses

General

You will be getting instructions per Email for installing the fuel lines and for the wing root filter but not for the brake lines.
Additional pdf files are available on this web page.
Additional pictures are available on this web page.
Each hose has a tag crimped on with VERY sharp edges where they cut the tab off. Consider using a glue gun and adding hot glue to the tabs so you don't cut yourself handling the hoses during install. Make sure the tags are not near anything they can touch later during flight and cut into.
The tags have a hose number stamped onto it, e.g. "H9" (Hose 9). The kit contains a small paper sheet that lists the function of each fuel hose number.
If you jumped ahead and installed the front seat floors and the seat rails, they need to come off to properly torque the fittings and fuel lines. Also install the control column and the side panels before assembling the front seat floors/rails.
Consider installing the control column temporarily to check interference with the fuel hoses.

Fuel Lines

Fuel Line Tags
- ASF103-10 R1 H1 and H2 - Under seat fuel return lines
- ASF103-10 R1 H4 and H5 - Under seat fuel lines
- ASF103-5 R2 H1 and H2 - Short fuel lines to wing root, filter output
- ASF103-1 R2 H3 and H4 - Long fuel lines for wing root, return fuel line
- 3 - not used for wing root filter kit
- ASF103-10 R1 H6 Valve to pump
- ASF103-10 R1 H7 and H8 Return fuel to valve
- ASf193-19 R1 H9 Pump to firewall
- 10 fuel return line
- ASH103-10 R1 H11 and H12 - fuel lines valve to rib fitting
If you have the setup for SDS fuel pumps, consider not running the hose from the fuel valve to the pumps in a straight line. The hose is very short and stiff and has no way to shrink / stretch if there is no bend in it. It also gives you a bit more freedom concerning how far to screw the fitting into the pump assembly. The milled distribution manifold may not allow you to add another full turn.
The fuel line(s) under the seats are held by F-1084A/F-1084B. Normally the metal lines are protected by plastic bushings with 0.375 ID / 0.5 OD. For the premade hoses, one can use rubber grommets stretched over the fitting after putting them in boiling water, suitable is ID 0.5 (1/2), OD .594 (19/32) (at Amazon). This requires enlarging the two forward F-1084 holes to 19/32 (two for SDS installations). Make sure the F-1084B top part is on in the right orientation as it is not symmetrical. Try to push the step drill bit away from the screw hole as you enlarge the opening. This minimizes the rubber grommet interference with the washer / nut when bolting the F-1084A and B parts together.
For the large existing fuel exit hole (which usually holds a rubber grommet for the metal line to come out), use the TCW machined washer / fitting set. Use the machined washer half on the inside and the plain washer on the outside. The outside washer needs to be trimmed on the lower side to not interfere with F-1099G (4 hole wing root fairing support).
For SDS installations, a second hole for an additional 90 degree fitting needs to be drilled into the side skin with a step drill. The location is specified in the premade fuel line manual (1 1/4 rear of rivet line, 1 1/2 inches up from side skin straight lower edge. The diameter is smaller than the existing hole, just large enough to hold the #6 fitting (9/16). This fitting needs a washer to increase the thickness. Consider using aluminum "AN SPACER, 6D" from Vans (needs to be trimmed a bit because there is a bend close-by.
Consider fluting and riveting F-1099G to the side skin before installing the fuel fittings and under-seat hoses as the full rivets will be hard to buck with the fuel system installed.
For routing the return line over the SDS pumps, consider replacing the two right AN3 bolts with two AN3-17 bolts, two washers, two 1.16” high #12 bored standoffs and two #7 Adel clamps.

Brake Lines

Brake line Tags
- ASF102-1 R2 H1 - left tunnel hose (shorter)
- ASF102-1 R2 H2 - right tunnel hose (longer)
- ASF102-2 R5 H1 and H2 - under seat hoses
- ASF102-3 R2 H1 and H2 - gear leg hoses

Page 38-3, Step 5: You won't be using the brass elbows, instead TS Flightline provides additional AN822-4D elbows, so all ports on the master cylinder will get them.
Page 38-7, Step 2: You won't be using the Nylon tee, instead TS Flightline provides an T-fitting that has two hose adapters and one for the brake fluid reservoir
The brake line with the 90 degree fitting goes to the left side of the T-fitting that is attached to the brake fluid reservoir (copilot left pedal).
The brake lines under the seats are going to the aftmost hole instead of the center hole if you need a return line.
The brake lines under the seats are held by F-1084A/F-1084B. Normally the metal lines are protected by plastic bushings with .25 ID / .375 OD. For the premade hoses, one can use rubber grommets forced over the fitting with a bit of heat, e.g. ID 0.375 (3/8), OD .469 (15/32). This requires enlarging the rear F-1084 holes on both sides to 15/32. Make sure the F-1084B top part is on in the right orientation as it is not symmetrical.
The three Adel clamps that hold each brake line along the bottom of the tunnel needs to be a #6 size (Vans supplies #5 clamps). The #6 clamp in the front and middle needs to be bent to have less height, otherwise it hits the bottom of the tunnel and the hole won't align. Bend it so you can just still get to the 8R8 screw with a screwdriver. The rear Adel clamp gets mounted pointing up (see next hint).
The instructions illustrate that the brake line dives down to get below the 45 degree fitting for the fuel line that uses the middle hole. If you do that, the brake line will be pushed against shop heads on the bottom of the tunnel. Better to have the brake line point a bit up and go above the center fuel fitting. The first Adel clamp should then point up instead of down.