As I will be installing the SDS EFI system to manage fuel flow in my RV-10, I had also previously purchased the Andair EFS 2020-D2-TMT fuel valve with return fittings. Unfortunately this valve does not fit into the stock fuel valve bracket from Van's due to the mounting holes on the Andair valve being further apart and the center hole requiring enlargement, so a modified bracket is required.
I again decided to follow other builders in fabricating a modified valve bracket and found a nice 3D printed template here (thanks Allen!). After printing the drilling template, I went to work to recreate it from 0.063" aluminum
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| Printed template alongside a piece of 0.063" aluminum cut to size and deburred, with the hole positions marked |
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| Drilling the center hole using a hole saw on the drill press |
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| Center hole came out perfectly positioned |
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| Lightning holes were also drilled using a smaller hole saw |
Next I match drilled the #12 holes (for AN3 bolts) and the #40 rivet holes
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| Bracket clamped to template for match drilling the remaining holes |
I then had to match drill the 3 rivet holes at each side of the fabricated bracket to the stock mount, as I would be cutting off the flanges of the stock mount and using those to mount the modified bracket.
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| Fabricated bracket centered and clamped to stock mount so that rivet holes can be match drilled |
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| After match drilling the rivet holes, I cut off the flanges of the stock mount making sure to leave adequate clearance from the rivet holes just drilled |
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| Stock mount flanges to be reused on the modified fuel valve mounting bracket |
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| All parts clecoed together along with the fuel valve itself. I was very happy with the fit, and all bolt holes lined up well |
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| Bracket from below |
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| I then countersunk the rivet holes in the top of the bracket for an AN426-3 rivet, and did the same in the flanges that attach to the tunnel side walls |
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| After priming and riveting, the fuel valve bracket is ready to go, and looks great! |
Time Taken: 3.1 hours
Dates: April 30 2025 - May 8 2025
Firewall Total Time: 27.3 hours
RV-10 Build Total Time: 1014.2 hours
Priming Total Time: 126.0 hours (not included in build time totals)
