What you need for the job:
Henderson Foot Pump Kit
1 metre square of foam, 75mm thick.
A kitchen knife.
A sheet of cardboard.
A drill and a hole saw bit.
A measuring tape
Before I started the job I removed the old foot rests as the foam that will hold the pump doubles as a foot rest. Make sure whatever foam you get when doubled together will reach the same point where you foot rest was before. You can slice down the first bit of foam used below if its too thick. We used this foam method as its strong and little can break or go wrong once its installed correctly.
Take a piece of cardboard a cut out a template of the bulkhead behind your foot rests.
This should fit in as accurately as possible.
Place the template onto the foam block and trace an outline onto the foam with a marker. Remove the template and draw another line 2cm around the outline of the template.
Using a kitchen knife cut along the outer line marked on the foam.
Trim the back of the foam at an angle with the knife. This will make it easier to push the foam into the kayak against the bulkhead.
Place the foam against the bulkhead. This takes a bit of time and requires you to sit in the boat and push the foam in with your feet. If you find the foam is too big, keep trimming small amounts of the edge of the foam until is fits in snuggly .
Cut out a second piece of foam following steps 2-4.
Place the pump in the centre of the of the second piece of foam and draw on the outline of the top part of the pump housing. Do not draw around the pieces that stick out for housings the screws. Cut out the shape following the marked line.
Turn the foam over and place the pump in to the hole until it meets the housings for the screws. Mark around the screw housings and mark a trench to receive the hose going from the back of the foam to the front. Cut out the bits where the screw housings are, just deep enough so the pump fits in flush with the foam. Cut out the trenches to fit the hose above and below the pump.
Attach the hose using the clips that come with the kit. Run the hose from the back around to the front of the foam. It can be held in place for the moment by putting a strip of duct tape across the bottom of the foam. The hose that lies on the bottom only needs to be long enough to reach the front of the foam. I recommend attaching the hose to the bottom of the pump first, cut it to length, leaving a good length to run from the top of the pump to the outlet later. If you wish you can also put screws through into the foam where the four screw housings are. At this point make sure that the pump is up the right way up, an arrow on the back of the pump shows the direction of the flow, make sure it points towards the hose that runs to the outlet.
Place the foam holding the pump into the kayak up against the first piece of foam similar to step 5. Gauge how far the top hose travels from the pump to go to the top of the kayak and mark this point inside the kayak. Take a measuring tape and measure from the edge of the front of the cockpit to this point inside the kayak. Copy the measure onto the outside of the kayak and mark the point. Using the drill and hole saw bit, drill a hole into the kayak at the place you marked.
Insert the outlet flange into the hole and secure using the nut provided. Attach the top piece of hose to the outlet from the inside of the kayak and secure the hose to the outlet using another hose clip. And you're done!