Day 169-170 9/21/24 -9/22 Fuel system rebuild, Windlass battery installation, Deck painting bow area.

 Deck

This weekend I sanded and fairing and  primed bow area with Epoxy Primekote primer, 2 coats in one day, next day put 2 coats of Interlux perfection on the bow area. 

  Bow is eventually painted Fuel system

Relapsing old fuel hoses and adding primary high volume filters with water separators for 30 and 10 micron before lift pump.

New fuel system diagramm

Real life filter setup

 

What changed vs original:

1. All hoses changed to A1-15 SAE J1527 5/8 
   
2. Added electric fuel pump right next to the tank.
3. 30 micron FG500 filter/separator
4. 10 micron filter/separator
5. Return port added to tank in opposite side than intake
6. Fuel return line from 10 micron filter back to the tank to be able to do polishing 
7. Check valve on the return line 
8. Return line from injectors returns fuel to tank
   

WHY

• Filters/separators added to make on engine filter last virtually forever.
• 3 stage filtering implemented
• Dual water separation for redundancy
• Electric pump plays 3 roles: 1) Makes air bleeding from low pressure part easy. 2) Fuel polishing capability to run fuel over filters w/o running engine. 3) in case of main lift pump failure electric pump may provide fuel to engine. 4) Emergency pumping through clogged filters (at least try).
• No-return valve to prevent air come back coming from the return line if for some reason polishing valve appeared open without service pump running.

Windlass 

Battery mount

Finally finished windlass battery and breaker setup.

 

Charging cable: negative connected to load side of the shunt, positive has inline 15A fuse  to protect the wire.

 

Windlass negative circuit goes to shunt, positive to the 50A breaker.

 

Battery monitor installed, but not connected yet.

 

Plans to Finish:

Connect battery monitor and route control wires to main battery box

Add Battery cover

Strap battery down 

Add LED indication that windlass power ON

[MAYBE] add cut-off relay controlled from cockpit