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2. Installation
The next step is to
install mounting screws on the pump, make a jig and
install the cockpit-side nuts and washers. The jig is just a scrap
of plywood cut to roughly the footprint of the pump with drill bit
guide holes for the pump mounting screws. You’ll use the jig
for three tasks: to position the pump on the bulkhead, to drill the
screw holes in the bulkhead and to position the nuts and washers
on the screw shanks.
• Place your screws through the screw holes
on the pump body and secure each with a lock nut.
While not absolutely necessary, this keeps the
screw ends from moving when you’re marking
their position on the jig and, later on, helps
in pushing the screws through the holes you drill
in the bulkhead. If your screws don’t have
fully threaded shanks, then you will have to ignore
this step. (Fully threaded screw shanks aren’t
always easily available in lengths over 3".)

• Cut
your jig material to size: 8 1/2" by 5 1/2".
• Place the pump, screw ends down, on the jig so that no part of the pump
hangs over the edge and the screws are all parallel.
• Trace around the end of each screw where it contacts the jig.
• Drill a 1/4" hole for each screw and check that all screws will go
into their respective holes at the same time.
• Separate the pump from the jig so that you can put the bulkhead-side nuts
and washers on the screws. First, back on the lock nuts, followed, in order,
by the steel and neoprene washers. Slide the jig back on the screws until it
is in contact with the pump. Adjust the nuts so that the neoprene washers are
secured between the jig face and steel washers.
To gain more room to work, you can remove your
foot pegs (or rudder pedals) and tracks.
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