I secured the crossover fuel line to the engine case:
Crossover fuel line secured to the oil sump
We then started working on the Showplanes intake installation. Because of the small "lip" on the tip of the throttle body, the servo plenum didn't fit immediately. I tried opening some slots on it and that made it go in a bit, but ultimately we just had to lay fiber around it and sand the inside - which also allowed us to set a better angle for it (turning slightly up):
Servo plenum with slots, barely fitting over throttle body
Servo plenum clearing the starter and alternator
Adjusting the position and angle of the servo plenum to add fiberglass to it
Cowling clearance below the servo plenum connected to intake plenum
Servo plenum after adding fiberglass, with a slight angle to it
With that in place, we match-drilled the intake plenum gussets, trimmed them to fit the intake plenums in place, and glassed them together:
Intake plenum gussets attached to baffle ramps
Intake plenum held in place, in alignment
Left intake plenum with gusset trimmed to bring it into the right position
Right intake plenum gusset trimmed to bring intake plenum into the right position
Intake plenums epoxied to their gussets
Last but not least, I added a couple layers of fiberglass to each side of the gussets, fully securing them in place:
Intake plenums with fiberglass securing the gussets
Intake plenum gussets reinforced with fiberglass layers
Next is glassing in the intake plenum caps to the servo plenum, and finishing the top side of the intake plenums by making a smooth ramp with homogeneous gaps to the cowl.
I replaced the original EFII hoses between the cylinders with the much nicer Aircraft Specialty ones, and attached the hoses to the regulator and post filter:
Original FlyEFII fuel hoses connecting the injectors
Aircraft Specialty integral firesleeve hoses connecting the injectors and regulator
Aircraft Specialty integral firesleeve hoses connecting the injectors and post filter
To use the cross-over hose from AS, I had to thcange the fitting on cylinder 1 to an AN826-6D ($15.50 at Spruce - what happened to hardware prices!?):
AN826 fitting connecting the right forward injector to the cross-over hose
Multiple fittings to connect the left forward injector to the cross-over hose
I'm still puzzles by having to use 3 fittings and a shorter hose on cylinder 2, but they say it's for better fitting the cowl so I believe them. Some day I may change that to another AN826 and a normal-length hose, after I know exactly how the cowl fits there.
Attaching the post filter was quite annoying - I tried the special Adel clamp tool, but the bolt was too short for that, so we ended up developing a new technique for these (which I'm sure someone will say is wrong - but if it worked, is it?) - we compressed the clamps, then ran safety wire at the base of their flange to hold them closed, and with that it was (comparatively) easy to get the bolt and nut in place:
Securing the post filter to the engine mount with Adel clamps
Safety wire trick to tighten the post filter Adel clamps in place
Post filter secured in place
The fuel pressure regulator conveniently had a 1/8" NPT port on the side, so I installed the fuel pressure sensor there:
Fuel pressure regulator with fuel pressure sensor attached
With this, there are only a few finishing steps left for the FWF fuel system - supporting the engine hoses again, adding the induction system drain hole, and securing the cross-over hose.
As the last firewall penetration (and start of the FWF fuel system), after lifting the engine and temporarily attaching it into place, I attached the Aircraft Specialty hoses to position the EFII/Aeromotive fuel pressure regulator:
Engine temporarily attached in place, still held by the hoist
Fuel pressure regulator attached to engine and firewall fittings to determine its position
At first I was having trouble finding a position and the hose seemed to short, until they pointed out that the hose can bend at a much smaller radius than I was trying, and then I found a good position, marked it, and then drilled the bracket holes (the holes are not accessible without removing the bracket from the regulator), and made a doubler:
Fuel pressure regulator doubler clecoed in place
Once that doubler (and others from the avioncis section) get riveted on, I can then insulate the firewall, re-attach the engine mount, and complete all the other FWF sections.
