Thanks Harry,

    I doubt if the pump is pumping more fuel than it should.  On the times
I
had
to shut off the fuel supply to stop the over flow, when I turned it back
on
it
took around 30 minutes for it to fill up to the top and start over flowing
again.  As mentioned, this only happened the first two times I flew it,
when
it
didn't have the plastic lexan tube over the wire gauge.  I've now replaced
it
with a new complete new cap.  After finishing the repair on my wing tank,
I
took
her up for two one hour flights.  It didn't overflow either of these
times,
and
the header tank remained full.  I suspect the new cap solved the problem.

Larry

[EMAIL PROTECTED] wrote:

> Larry,
>
> I doubt you hurt the fuel pump....But, the problem lies with pumping
more
> fuel into the tank than the overflow line will take care of.//...
>
> The fuel pump should have a restrictor in the outlet side , restricting
the
> max flow to about 6 gal /hr...there is a proper restrictor filling for
the
> pump....;  and the overflow line needs to be cleaned out. If an airplane
> sits
> for a long period, then the fuel fuems slowly evaporate and leave a
crust
of
> shellac on the inside of the fuel line return. This eventually leads to
a
> cloging of the return line just where it exits the tank....
>
> I was surpirsed to find mine cl;ogged after sitting about three
months....
>
> Remove the fitting, and using a flexible wire clean the  "el" fitting in
the
> tank. Then blow into the header tank tank --no more than 1 psi, and all
the
> stuff should blow out. Check the line to the wing tank, to be sure it is
> free, also....
>
> To ckeck for plugging, one can blow into the header tank and hear air
> bubbles
> in the wing tank....You should be able to easily blow air thru this
> system....Maybe have someone slse listning at the wing tank. I could
easily
> hear the air passage and bubbles after cleaning my fittings....
>
> Possibly the line will clear itself after becoming slightly plugged, by
the
> flow of gasoline ???? --once the a/c is again being used..
>
> .But it is not nice to have gasoline flowing out of the header tank, and
> into
> the engine compartment and cockpit.....
>
> After my cleaning, and re-assembly, I had No more problem...
>
> Harry Francis
> 93530
> Blacksburg, VA
>
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