I recently asked for input from builders on routing the hydraulic lines from the main landing gear to the hydraulic manifold in the Glasair II-S RG. The following is a response I received from Neal Garvin:
Don't put the manifold on the rear shear web. Put two Tee fittings in the rear spar to connect the Up lines together and the down lines together on the front side of the spar. Then with the Tee facing aft through the rear spar you just need to run two lines back through the control tunnel to the hydraulic manifold mounted somewhere behind the pump - out of the way. Put the pressure switches back there in the manifold also. You can put a second set of Tee's in the lines and Tee off for the nose gear hyd lines using 90 degree bulkhead fittings going down through the wing bottom skin either in front of the rear spar or up in front of the flap torque tubes somewhere. Put the 90 bulkhead fitting facing fwd on the bottom of the wing skin. Run the nose gear hyd lines aft from the firewall to a pair of 45 deg bulkhead fittings mounted on a fiberglass bracket on the sides of the rudder pedal vertical mounts. Angle the fittings down to go aft over the top of the fwd belly pan rib and point down under the wing leading edge. After you mount the wing, you make up a set of lines to connect the fittings in the bottom of the wing to the ones on the fuse rib.
The brake lines (if you use -3 alum in place of nylaflow) can be mounted in the same way on the pilot side with a 90 deg bulkhead fitting going up into each seat pan area for connection to the lines running out to the wheel wells next to the gear hyd lines. We ran our alum -3 brake lines through the B-ribs just fwd of the gear hyd lines, but didn't use an extra bulkhead fitting in the wheel well. Just ran the line thru the hole and flared it after.
You are going to use a down pressure switch (like the GIII) to shut the pump off on the down side, right?? Get rid of that silly gear control relay board and reliance on the side brace microswitches to shut the pump off. There is no relation to building up 800 PSI down pressure and the closing of a microswitch in the side brace arm. The microswitch is "digital" - on or off. The pressure is analog - it can be anywhere from 0+ to 1000 psi (the internal bypass pressure of the pump on the down side). Making it work with the finicky adjustments to the microswitch and length of the actuating rivets is not an easy magic trick.
Get the Down pressure switch from S-H that is used on the Glasair III gear control system. Also get the diode board so you can wire all 6 gear position lights with a test button. You will also need the adjustable hyd flow restrictor valve to put between the pump and the down pressure switch to keep the pump from cycling on/off/on/off/on as the gear goes down. (the gear can't keep up with the volume of fluid the pump puts out causing the pressure to build to fast as the gear is still going down). Emerald aircrafters sells a kit to do this but you can do it all with the parts above and a schematic. Let me know if you want a copy.
Ever see a Glasair II RG owner bending under his wing to kick the side brace arm to make the pump switch on so he has adequate down pressure before starting?? Pretty rediculous. Using a pressure switch to control the down pressure guarantees that if the pressure goes below about 600 psi, the pump will turn on, regardless of the position of the sidebrace microswitch. Also, if any one sidebrace microswitch gets out of adjustment, you will have an unsafe light, but still have full pressure and down and locked side braces.