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Hints for installing TS Flightline hoses: Difference between revisions
Hints for installing TS Flightline hoses (view source)
Revision as of 14:22, 19 April 2025
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* 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. | * 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. | * 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 Lines ==== | ||
| Line 13: | Line 15: | ||
** ASF103-1 R2 H3 and H4 - Long fuel lines for wing root, return fuel line | ** ASF103-1 R2 H3 and H4 - Long fuel lines for wing root, return fuel line | ||
** 3 - not used for wing root filter kit | ** 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 | ** 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.<br>[[File:2023-09-04 14-32-38.jpg|467x467px]] | * 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.<br>[[File:2023-09-04 14-32-38.jpg|467x467px]] | ||
* 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 | * 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) ([https://www.amazon.com/dp/B08XQ4WTKF 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 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. | * 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. | * 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.<br>[[File:Screen Shot 2024-01-21 at 10.38.03 PM.png|496x496px]] | |||
==== Brake Lines ==== | ==== Brake Lines ==== | ||
* Note: if you received your Flightline hoses from Van's as part of the Beringer wheel/brake kit you received the basic version without the anti-lock system or the parking brake. | |||
* Brake line Tags | * Brake line Tags | ||
** ASF102-1 R2 H1 - left tunnel hose (shorter) | ** ASF102-1 R2 H1 - left tunnel hose (shorter) | ||