Ameer Randolph
Bending RV-12 fuel lines is a complex process that requires careful planning and execution. It involves a series of precise bends and adjustments to ensure a proper fit within the aircraft's fuel system. The process typically begins with straightening and cutting the appropriate length of aluminum tubing, followed by flaring one end and sliding on a sleeve and nut. Multiple 90-degree bends are then made to form an offset between the fuel pump and the bulkhead, with additional bends as needed to accommodate specific components such as the fuel flow meter. The process requires specialized tools and knowledge of aircraft assembly, and modifications may be made to the fuel lines during construction to enhance functionality and accessibility.
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What You'll Learn
Bending the RV-12 fuel line to accommodate a fuel drain modification
Step 1: Straighten and Measure
Start by straightening out the required length of 3/8" aluminum tubing, which is the standard size for the RV-12 fuel line. Measure and mark the tubing according to the plans. The first bend will be made at the marked point. It is important to have some extra fuel line to accommodate any adjustments or errors.
Step 2: Flaring and Sleeving
Flares are created at the ends of the tubes using a flaring tool, such as the Parker Rolo 37-degree flaring tool. This tool is designed specifically for aircraft fuel line angles, which differ from those in automotive or plumbing applications. After flaring an end, slide a sleeve onto the tubing. The sleeve must be added before bending because it will not fit around a bend.
Step 3: Bending the Tubing
Now, you can begin bending the tubing to match the diagrams in the RV-12 plans. Use a tubing bender to create the required angles, typically 90-degree and 15-degree bends. It is crucial to secure the tubing properly during this process to avoid damage. One creative solution to secure the tubing is to use a pin punch with masking tape to prevent scoring the inside of the tube.
Step 4: Fuel Drain Modification
To accommodate the fuel drain modification, stop before making the final 90-degree bend that goes up to the fuel tank. This shift from the standard plans allows for the addition of a fuel drain under the fuel tank. This modification enhances fuel quality checks by providing access directly at the tank.
Step 5: Final Adjustments
After completing the bends, make any necessary adjustments to align the fuel line with the bulkhead fitting. Fine-tune the positioning of the fuel line to ensure it conforms to the diagrams and measurements in the RV-12 plans.
By following these steps and making any necessary adjustments along the way, you can successfully bend the RV-12 fuel line to accommodate the fuel drain modification. Remember to refer to the official plans and diagrams for precise measurements and angles, and always prioritize safety and accuracy when working on aircraft fuel systems.
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Using a pipe-bending tool to achieve the desired shape
Bending RV-12 fuel lines can be achieved using a pipe-bending tool. The process requires careful planning and execution to ensure a precise and desired outcome. Here is a step-by-step guide on using a pipe-bending tool to achieve the desired shape:
First, it is important to select the appropriate pipe-bending tool for the job. There are various types of bending tools available, each with its benefits and drawbacks. For RV-12 fuel lines, a dedicated pipe-bending tool specifically designed for this purpose is ideal. These tools can be purchased or rented, depending on your needs and budget.
Once you have the right tool, the next step is to plan the bends carefully. Mark the pipe according to the required measurements and angles. It is crucial to ensure that the pipe is the correct length before bending, as correcting it afterward can be challenging. Take into account the number and angles of the bends required, and ensure that the pipe-bending tool can accommodate these angles.
Now, you can begin the bending process. Secure the pipe in the pipe-bending tool, following the instructions provided with the tool for safe and proper usage. Slowly and carefully bend the pipe to the desired angle, ensuring that you follow the marked measurements. Take your time during this step to avoid mistakes, as bending too sharply or at the wrong angle can ruin the pipe.
After completing each bend, check the pipe's integrity and ensure no kinking or cracking has occurred. Some pipes may require additional support or filling with a non-compressible substance to prevent collapse during bending. It is crucial to work slowly and methodically, as rushing may result in errors.
Finally, once all the bends are complete and you have achieved the desired shape, carefully remove the pipe from the bending tool and inspect it. Ensure that the pipe meets your requirements and that all bends are accurate and smooth. If any adjustments are needed, do so carefully, as making corrections to a bent pipe can be tricky.
By following these steps and using a pipe-bending tool, you can achieve the desired shape for your RV-12 fuel lines. Remember to take your time, plan carefully, and work methodically to ensure a successful outcome.
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Adding a fuel drain sump below the fuel tank
The RV-12 fuel line modification involves adding a fuel drain sump below the fuel tank. This modification is made to the RV-12 Light Sport airplane, which is typically built as an Experimental Light-Sport Aircraft (E-LSA). The process involves bending the fuel tank to fuel pump line to accommodate the fuel drain sump.
The first step is to straighten out two feet of 3/8" aluminum tubing. The tubing is then cut and prepped, and a nut and sleeve are slipped over the end. The end of the tube is flared, and the first 90-degree bend is made. This is followed by another 90-degree bend and a 15-degree bend to match the template in the aircraft's plans. The final 90-degree bend is made upwards towards the tank, referencing the aircraft's plans.
The fuel line is then attached to the fuel pump, and the fuel supply and return lines are connected to the tank. A hole is cut into an inspection plate below the fuel tank to allow the fuel valve to protrude. This modification allows for easy access to check the fuel quality directly at the tank.
The fuel drain sump modification is a popular choice for builders, as it allows for convenient fuel quality checks and can be incorporated during the construction process. It is important to note that the RV-12 kit requires very little extra help during construction, making it a suitable choice for those interested in building an airplane from a kit.
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$13.59
Making an S-type bend in the fuel line
Making an S-type bend in a fuel line can be tricky, and there are several methods that can be used. One common method is to use a bending spring. These are available at your local hardware store in the plumbing section. You slip the correct size over the fuel line, and it supports the line while you bend it with your hand. This method is especially useful for 90-degree bends.
Another method is to use a stiff wire. You bend the wire into the desired shape, insert it inside the fuel line, and then place it in warm water to heat-soak for about five minutes. Then, pull it out and place it into cold water to set the shape. This method works best with thin-walled fuel lines.
If you are working with a metal line, you can also try filling the line with water, capping the ends, and freezing it for a short time. You can then bend the tubing without kinking it with a tubing bender. After bending, allow the ice in the tubing to melt, and then blow out the tubing with an air hose to ensure it is completely dry before installing.
Additionally, you can use a heat gun to shape the fuel line. This method can be tricky, as you need to determine the right amount of heat to use without weakening the hose. It may be helpful to use a pre-formed pipe as a guide when using a heat gun.
Finally, you can use steel, copper, or nickel brake tubing to make sharp bends, joining them to the fittings with short straight pieces of hose. This method is easier than using a metal line, as it avoids the need for extra connections. However, it is important to avoid running metal lines close to heat sources, as it may cause the fuel to boil or vapor lock.
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Using a coat hanger to achieve a 90-degree bend
Bending an RV-12 fuel line by 90 degrees can be achieved by using a coat hanger. This is a cost-effective method, but it is important to note that it may not be as precise as using specialized tools. Here is a step-by-step guide on how to achieve this:
Firstly, you will need to straighten out the coat hanger and cut it to a suitable length. It is recommended to make it a little longer than the fuel line to allow for easier handling. Then, bend the coat hanger to the desired shape, in this case, a 90-degree angle. It is important to bend the hanger slightly more than 90 degrees to account for recoil.
Next, insert the coat hanger into the fuel line. Ensure that the coat hanger is securely in place and fits snugly inside the hose. Once this is done, you can begin the process of heating the setup. There are a few methods to achieve this: boiling water, a heat gun, or a lighter. If using boiling water, submerge the fuel line with the coat hanger inside completely in the water until it is fully heated. Then, dunk it in cold water to set the shape. Alternatively, a heat gun or a lighter can be used to apply direct heat to the fuel line, but be cautious to avoid overheating and potential damage.
After the fuel line has been sufficiently heated and shaped, remove the coat hanger. It may be easier to remove the hanger if it is made of copper, as steel can be more rigid. Now, you should have a fuel line with a 90-degree bend. It is important to note that this method may not always work, as some fuel lines are manufactured with a specific shape that cannot be altered. Additionally, be cautious to avoid kinking the fuel line, which can restrict fuel flow.
There are alternative methods to achieve a 90-degree bend in an RV-12 fuel line. These include using a tubing bender, packing the line with sand, or using pre-bent lines. Each method has its advantages and disadvantages, so it is essential to consider the available tools and level of precision required before proceeding.
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Frequently asked questions
The RV-12 aircraft's fuselage requires a few steps to bend the fuel lines. First, straighten out two feet of 3/8" aluminum tubing. Next, slip the nut and sleeve over the tubing and flare the end of the tube. Then, make the first 90-degree bend. You can also make an S-type bend in the fuel line. Finally, bend the second 90-degree bend and then the 15-degree bend to match the template in Figure Van's Aircraft's plans.
You can use a pipe-bending tool to bend the RV-12 fuel lines. It is also possible to fill the tubing with a non-compressible substance to prevent collapse and then dunk it in boiling water to set the shape.
The tubing used for the RV-12 fuel lines is 3/8" aluminum tubing.
