Fuel line routing question

[Allen B]

Does anyone have a picture of how they routed the aft fuel lines for the co-pilot side? With the cargo door formers in the way I’m not sure how to route the lines where they’ll be the least in the way. I feel like the pilot side is in a pretty good position but I’m stumped when it comes to the co-pilot side. Any advice would be greatly appreciated. Thanks, Allen

 

[TimTall]

I struggled with that as well. I've only got one picture where the routing is visible... I routed the line down the inside of the door post where it would be completely exposed in the cabin but it was an easy, straight line. I then bent up a cover piece that essentially extended the door post into the cabin by 3/4" to cover the fuel line. I'll take some pics if i get to the hangar later todayView attachment 102263

 

[Allen B]

Thanks. I’d love to see some pics because I’m stumped.

 

[TimTall]

Hopefully this helps. I'm happy with the way it turned out.

 

[TLyon]

Not fully secured yet, but this is what I bent up a couple weeks ago.

Thanks for those photos Tim, I’ve been trying to picture what it will look like covered up.

 

[Allen B]

View attachment 102266View attachment 102267View attachment 102268View attachment 102269View attachment 102270View attachment 102271View attachment 102272View attachment 102273View attachment 102274View attachment 102275
Hopefully this helps. I'm happy with the way it turned out.

These are extremely helpful. Thank you. Aside from hiding the tubing you found a way to protect it from passengers. Looks great as well. Thanks.

 

[Allen B]

Not fully secured yet, but this is what I bent up a couple weeks ago.

Thanks for those photos Tim, I’ve been trying to picture what it will look like covered up.

Thanks for this. That’s as far as I got as well. It seems like bending it around the inside of the door former is the way to go. I like how he fabricated a cover to keep unwanted hands off of it. What are you planning to use to secure the line to the back of the door post?

 

[TLyon]

Thinking uncushioned adel on the steel to padded adel on the fuel line. I’m also looking at some small angle brackets where it turns under the doors. I like that concept, but I’m not sure there’s room for that on the vertical run.

 

[PhilBC]

What we did so far.

 

[Allen B]

What we did so far.

Thanks. It looks like everyone is bringing the line around the former and not through it. I think I’ll take the advice of the group consensus. Thanks again

 

[Battson]

Thanks. It looks like everyone is bringing the line around the former and not through it. I think I’ll take the advice of the group consensus. Thanks again

Be sure to put lots of protective wrap around the fuel line here. It's one of the longest unsupported fuel line runs, so vibration and chafing is a consideration.

 

[Allen B]

Be sure to put lots of protective wrap around the fuel line here. It's one of the longest unsupported fuel line runs, so vibration and chafing is a consideration.

Thanks for the advice. It seems like people are using Tygon tubing for the areas where the line passes through the formers. I ordered some and it’s on the way. I was also thinking of padded adel clamps where appropriate. Any other options you can think that would be preferred?

 

[TimTall]

For the long run down the door post i put a layer of double wall heat shrink over the aluminum fuel line, then slid a wire protection sleeve over that. Then, I put a couple wraps of electrical tape around the tubing before taping it to the door post in a couple spots. Padded adel clamps at the top and bottom where there was room for them in the wing root and below the door sill. The tape is hidden because i wrapped the entire door post with the aluminium cover. The cover is removable for inspection. There's no sign of chafe on the fuel line after 150hrs and i doubt there ever will be because it's held tightly to the door post with the tape. Change the tape every few years.

 

[Battson]

Thanks for the advice. It seems like people are using Tygon tubing for the areas where the line passes through the formers. I ordered some and it’s on the way. I was also thinking of padded adel clamps where appropriate. Any other options you can think that would be preferred?

I mostly got some clear plastic fuel line, cut it to length, split it open with a box cutter (carefully!) and table tied it onto the aluminium fuel line.
I also used spiral wrap electrical tubing, in places which had bends or were hard to reach.