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Old 01-31-2011, 07:51 AM   #1
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The Fuel System Upgrade Project

I wanted to start a new thread to have a single point of reference to chronicle and ask questions in regards to my current fuel system upgrade project. As posted in the fuel polishing thread, I am going to reconfigure Skinny Dippin's entire filter rig to be a multi-stage filtration and add a simple fuel polishing circuit.

The current system (I had pics, but the camera got stolen with them in the card) was two Racor 500 filters (and an Algae X). One filter was dedicated to the main engine and the other for the genset. The return line from the main engine dumped into one tank and the genset into the other thru 1/8" (or 3/16") fittings.

I spent this weekend dismantling the old system and now have a pile of parts in the dining room. It, of course, can apart very easily. Now the hard part begins.

The plan is to mount the entire system to a 1/2" piece of Starboard 20"x35" for easy removal and service. Currently, I have received a new Raycor 500 from Defender and a 1/4 horsepower A/C motor, Procon 60 gph pump, and a check valve from Grainger. I have also found two hydraulic shops (one here at home and one down at the boat) that have warehouses of parts and the willingness to help with my project.

I'll take pictures along the way and hope you guys can offer up some good advice.

Thanks,
Tom-
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Old 01-31-2011, 08:35 AM   #2
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The Fuel System Upgrade Project

Here are a few pics.

1) The final-ish drawing.
2) The pile of parts removed Saturday.
3) The two tiny returns.

-- Edited by GonzoF1 on Monday 31st of January 2011 09:37:33 AM
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Old 01-31-2011, 10:25 AM   #3
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RE: The Fuel System Upgrade Project

Here is the mock-up on plywood. The plan is to take it to the hydraulic shop all mounted and spend an hour or so plumbing it up.
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Old 02-01-2011, 03:08 PM   #4
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RE: The Fuel System Upgrade Project

The next step was to spend today cleaning and rebuilding the old 500's. They were pretty filthy and whomever worked on them last must not have been reading the directions. One ball valve seat was completely gone and the other was installed backwards. But, nevertheless, a little elbow grease and Dawn liquid soap did the trick.

Then I went to Ace Hardware and got some 1.25" stainless bolts and locking nuts and mocked them onto the plywood. I may have to redesign the mounting because it won't be easy to take them off the board in the future without taking the board down completely to get a wrench behind it (something that should be easy to do), so I may think on that a while.

I do have a question: This rig (in order to save some cash) has three different model year filters with three different configurations of drains and ports. Nothing REALLY major EXCEPT that on two, there are two different size in's and out's. Anyone see an issue with this? (noted in picture #3)

Pic 1) Mock-up
Pic 2) Fresh and clean filters
Pic 3) One has 3/4" 16 UNF (whatever that means) and the other has 3/8"

Tom-
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Old 02-01-2011, 03:18 PM   #5
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RE: The Fuel System Upgrade Project

I see no issue with the different size ports. Once you have adapters in pace it will be invisible.

If you are going to use Starboard in the end product, *why not simply tap the* mounting holes.
It should be strong enough to support the filter units.

Or if you insist on thru bolting with nuts, make some "stand-offs" so the mouting board has a space behind it to get a wrench on the nuts.

OR...use "carriage bolts" (the ones with a square under the round head) from behind and draw them into the starboard...they will stay in place that way. The nuts will be on the outside.
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Old 02-01-2011, 05:54 PM   #6
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RE: The Fuel System Upgrade Project

Port size is a non issue as your flow rate is only 1 gallon per minute. The ports should easily support 3/8" or 1/2" fuel lines.

Ted
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Old 02-01-2011, 06:05 PM   #7
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RE: The Fuel System Upgrade Project

Tom,
I think the mockup is a great idea. Where did you source your timer from?
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Old 02-01-2011, 06:12 PM   #8
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RE: The Fuel System Upgrade Project

Looks great Tom.* You'll love that pump.
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Old 02-01-2011, 06:53 PM   #9
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RE: The Fuel System Upgrade Project

Quote:
Forkliftt wrote:

Tom,
I think the mockup is a great idea. Where did you source your timer from?
Timer, pump, motor, and check valve are all Grainger.

I'm heading to the hydraulics warehouse tomorrow to start the plumbing.
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Old 02-01-2011, 08:25 PM   #10
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RE: The Fuel System Upgrade Project

Quote:
jleonard wrote:

I see no issue with the different size ports. Once you have adapters in pace it will be invisible.

If you are going to use Starboard in the end product, *why not simply tap the* mounting holes.
It should be strong enough to support the filter units.

Or if you insist on thru bolting with nuts, make some "stand-offs" so the mouting board has a space behind it to get a wrench on the nuts.

OR...use "carriage bolts" (the ones with a square under the round head) from behind and draw them into the starboard...they will stay in place that way. The nuts will be on the outside.
Thanks for the tips. I thought about stand-off nuts. I'd have to use a combo of carriage bolts and stand-off because I feel the need to use nylon locking nuts to avoid them backing off. But, at 7 knots, there isn't TOO much vibration down there. Still, anything worth doing is worth over doing.

We'll see where I end up. I have many step to take before I get there.
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Old 02-02-2011, 06:35 AM   #11
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RE: The Fuel System Upgrade Project

*"nylon locking nuts"

Just use a dab of loctite. You'll be buying some (most likely) for the fittings , use it for the nuts too.
*
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Old 02-03-2011, 12:26 PM   #12
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RE: The Fuel System Upgrade Project

Well, the hydraulics store(s) was kind of a bust. While they can get some of the parts and have some in-stock, they don't really provide the one-stop solution I was looking for. Soooo... looks like it's time to hit the Grainger catalog and do most of this myself.

I have a few questions.

Should I just stay 3/8" I.D. for all the fuel lines? I was thinking 1/2" for the polishing side, but I would like to keep it consistent throughout the entire system so I don't have to carry two different size spares. Although, the line from the tanks will probably be 1/2.

Should I look for the hose barbs to be extra long to allow for double clamps?

I have had the hydraulics guys try to sell me on "Push Lock" fittings. They don't require clamps as they have two large barbs that lock onto their hose. They hold more psi than my system can provide and cannot be pulled off. They must be cut off. I am not an expert, so I don't know if this is common on boats.
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Old 02-03-2011, 01:04 PM   #13
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The Fuel System Upgrade Project

Quote:
GonzoF1 wrote:


I have had the hydraulics guys try to sell me on "Push Lock" fittings. They don't require clamps as they have two large barbs that lock onto their hose. They hold more psi than my system can provide and cannot be pulled off. They must be cut off. I am not an expert, so I don't know if this is common on boats.
If you use Push Loc fittings, they should only*be used*with*Push Loc hose.* Is the hose USCG approved?

*


-- Edited by Larry M on Thursday 3rd of February 2011 02:08:35 PM
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Old 02-03-2011, 01:57 PM   #14
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RE: The Fuel System Upgrade Project

For nuts take a look at " Tee nuts" available in SS if you like. they are an ID threaded mushroom shaped insert which is put the hole in from the back side of the wood, a couple of prongs sink into the wood and keep the insert from turning when the bolt is screwed in or out. The bolt is holding in metal yet the back of the boart is virtually flush.
http://www.boltdepot.com/t-nuts.aspx I have seen them at Lowes also

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Old 02-04-2011, 06:47 PM   #15
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RE: The Fuel System Upgrade Project

Is the Shields fuel hose sold at West Marine acceptable to use for this rig?

(Grainger fittings and stuff on order )
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Old 02-04-2011, 09:36 PM   #16
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The Fuel System Upgrade Project

Have you considered adding a squeeze bulb priming system? I added multistage filtration by adding a canister type (looks like an oil filter) fuel filter plumbed in series with my Racor 900 filter. Adding squeeze bulb priming made priming the engines after a filter change a breeze and eliminated the necessity of carrying fuel to refill the racor.

-- Edited by timjet on Friday 4th of February 2011 10:37:58 PM
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Old 02-05-2011, 06:45 AM   #17
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RE: The Fuel System Upgrade Project

Quote:
timjet wrote:

Have you considered adding a squeeze bulb priming system? I added multistage filtration by adding a canister type (looks like an oil filter) fuel filter plumbed in series with my Racor 900 filter. Adding squeeze bulb priming made priming the engines after a filter change a breeze and eliminated the necessity of carrying fuel to refill the racor.

-- Edited by timjet on Friday 4th of February 2011 10:37:58 PM
No need. Gravity does fine. Just need to crack the tank valves with the filter top off and it fills up easily.

*
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Old 02-05-2011, 07:17 AM   #18
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RE: The Fuel System Upgrade Project

With 1/2 full tanks I doubt that your tanks have enough head to fill the on engine filter. That is the purpose of the squeeze bulb - to fill the on engine. On my Perkins the hand lever on the*lift pumps do this job.
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Old 02-05-2011, 09:55 AM   #19
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RE: The Fuel System Upgrade Project

Quote:

No need. Gravity does fine. Just need to crack the tank valves with the filter top off and it fills up easily.
Ditto!

*
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Old 02-08-2011, 07:14 PM   #20
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RE: The Fuel System Upgrade Project

The Man-Fairy (UPS guy) came today and brought brass fun!

1) Box of items from The Man Bible!
2) Mocked-up intake manifold.
3) Looks like the total mock-up reveals that I might need a little bit more space.
4) One concern I have is that the barbed end of the 90-degree end (on this output manifold) is a tad short. It will take some testing to see if it needs redesigning.
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