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How to: Vapor Return Lines in fuel tanks

Posted: Wed Nov 30, 2005 5:54 pm
by captain_john
Hi All, I am putting this together for several reasons.

1) I haven't found anyplace on the web where someone assembled a "How To" in a place that is open to commentary and allows us to work collaboratively.

2) I have been asked by a few people now to do this.

3) I am an educator and I like helping people out, even if I am wrong!

:wink:

I am not saying that my method is right! By all means no! It may not be, but I am willing to stake my life on it! You may stake yours on it too?

First, what is vaor return? I understand it to be the excess fuel that is delivered to the firewall forward area when the throttle is pulled back after a high flow situation. There is also a certain amount of fuel residing there at all times, even when you have pulled mixture to idle cutoff.

The EFI system sends this fuel back to the tanks for recycling.

Some peole have reintroduced this fuel/vapor mix back into the fuel feed line just after the tank selector valve with good results. I chose to return it back to the tank for cooling and mixing with the bulk supply.

Others have just dumped it overboard. I personally have cost, environmental and safety concerns with this method.

The Eci EFI system (which is't yet available) and the auto conversions need a Vapor Return (VR) system to work properly.

Eci had a nice .pdf outlining the components of their fuelie system, but I cannot seem to locate it right now. If anyone has a copy of it, please let me know. We can post it here.

In addition to the extra work of the VR lines you will need a duplex fuel selector from Andair like this one:

Image

I have noticed that no one seems to be giving these away at halloween or for Christmas near me, so be prepared... they are the better part of $600!

:o

With cost not being an object, this shouldn't be a problem!

Anywhooooo, you will need to get some additional 1/8" elbows for this job. I installed mine like this:

Image...so they would clear the capacitive sender plates.

The bottom one is for the VR line. This is what it looks like from the inside:

Image

You can see the nipples sticking into the first bay. (hahaha, I said NIPPLES! Sophomoric humor, I am good for that!)

I saved the root rib for last, so I could insert the tubes into position, rivet the rib and then tighen the fittings... in that order.

Image

This is the view of the left hand tank, second rib as the tubes pass through the rib. I kept the vent line OEM and ran the VR just below and to the rear of it. The flop tube is totally clear of it.

Image

... through the next bay:

Image

...and the next one too, until it reaches the center of the tank:

Image

...where I abruptly end it. Here it will dump into the center of the bulk supply for mixing and shouldn't affect the total capacitance read by the senders, as it should have minimal effect on the dielectric of the total quantity.

What do you guys think? Did I do OK? Anything to add?

I threw the poll on here for $h!+$ and giggles!

I am happy with the product! Hopefully it won't leak!!!

:drink: CJ

Posted: Wed Nov 30, 2005 5:58 pm
by captain_john
Oh yah...

See also the thread I posted on VAF before I had any information to go on:

http://www.vansairforce.com/community/s ... eturn+line

...and I am the one who voted with the first disparaging comment!

:wink: CJ

Posted: Fri Dec 02, 2005 7:52 am
by greylingr
Thanks John

Posted: Fri Dec 02, 2005 3:26 pm
by captain_john
You are welcome, Rudi!

I do hope it is helpful to you!

Feel free to ask questions.

:) CJ

Posted: Tue Dec 06, 2005 6:37 pm
by RV7Factory
Great stuff CJ... Very useful!!!

That link you are looking for moved. Here is the new URL...
http://www.eci2fly.com/pdf/FIS11x17.pdf

Cheers,
Brad
www.RV7Factory.com

Posted: Tue Dec 06, 2005 9:57 pm
by captain_john
That's the stuff! Thanks Brad!!!

:wink: CJ

Posted: Wed Dec 07, 2005 10:27 am
by Spike
Thanx Guys. I put some links to this and some of ECI's other great resources in the Document Share.

-- Spike

Posted: Wed Dec 14, 2005 8:25 am
by greylingr
HI John,

Looks like you used AN-4D fittings for the vapour return, just like the vent. The main fuel line is AN-6D from the tank.
1) Do you foresee any problems in going from bigger to smaller?
2) Looks like the Fuel selector has AN-4D and -6D fittings?
3) Otherwise how are you going to reduce from -6D to -4D.

Thanks
Rudi

Posted: Thu Dec 15, 2005 5:53 pm
by captain_john
Rudi,

I chose to go with the -4 sized fittings because I just don't think there will be that much fluid returning to the tank. I am making a guess, but if I am correct the vapor will "burp" fairly fast back to the tank. This shouldn't require a line as large as the feed as some fuel will be consumed in the process. Besides, issues normally arise (and are feared the most due to long ground operations) on takeoff where fuel consumption is at a high rate.

The Andair FS 20-20 D2 has -6 feeds and returns. If I were to do it today, I would run a -6 back to the selector and neck it down either at the tank or at the selector on the tank side. In my estimation, this system is far superior than not having a system at all and should prove to be reliable.

Also, there is a nice article in the 24 years of... where they discuss the use of Mogas and the use of Vapor Return lines. Good reading if you have the book. If not you need this book!

8) CJ

Posted: Fri Dec 16, 2005 11:05 am
by greylingr
Thanks John,

I have to book, but did not see the article yet, will look tonight!

Regards
Rudi

Posted: Mon Nov 20, 2006 6:58 am
by captain_john
TTT

Once again for renewed interest gathered from other sites and for new readers of this forum.

Update:

In thinking about the utility of this modification, I am not sure that I will immediately make use of both return lines. If I were to do this today, I would plumb one and leave the other plugged. This would mandate operation from the plumbed tank until sufficiently depleted to switch to the other tank.

My reason for doing this now is to not disallow use of let's say an ECI fuel injection system and to keep my options open to engines of the future. Engine technology is on the verge of delivering significant improvements to us and when a good one comes along, I want to be able to evaluate it.

:) CJ

Posted: Mon Nov 20, 2006 3:13 pm
by svanarts
I'm not going to FI my engine but the thread was interesting nonetheless.

It's also good to see our South African movie maker on the forum. Welcome Rudi!

Posted: Mon Nov 20, 2006 10:37 pm
by Dan A
Don't really know why you guys are going with Air performance injection systems. I used the Precision Air Silver Eagle, the non certified version of the Bendex RSA, and I only had to run one fuel line. No return lines. After 135 hrs, it runs perfect! 8)
Dan

Posted: Tue Nov 21, 2006 12:14 am
by jim_geo
I'm with ya Dan. Seems like a good system to me.

Posted: Tue Nov 21, 2006 6:57 am
by captain_john
I gotta say that I am on the fence.

I like the fact that AP is on the east coast and I can run down there and do the balancing class real easy!

They want you to bring your own plane and work on it there!

I am real cool with that!

8) CJ

Posted: Fri Nov 24, 2006 10:23 pm
by svanarts
Way to go CJ! You made the top center headline above the fold on the RV Builder's Hotline! :yay:

Posted: Fri Nov 24, 2006 10:28 pm
by captain_john
WOW! I are somebody now!!!

I tells ya, I would gladly give up all this fame for just a few million dollars!

:lol: CJ

Posted: Fri Nov 24, 2006 10:37 pm
by svanarts
I bet you'll even be in the phone book soon!

Posted: Fri Nov 24, 2006 10:43 pm
by captain_john
Nawwww, no phone book for me!

STEALTH MODE!!!

8) CJ

Posted: Sat Nov 25, 2006 1:43 am
by jim_geo
CJ how important do you feel it is to return vapor to the outboard end of the tank?