Hi Craig,
Just a few last comments on this thread.
By your description of your filter, you have what I believe it would be best called a filter bypass feature rather than a pressure relief valve. I think we both agree why this is necessary. If you were to plug the filter with contaminants it would be best to keep the engine running to return to the airport. Even at the expense of putting contaminants in the whole system.
The other reg that I did not display talks about quantity. It uses terms like "sediment bowl" which would indicate that be at has the capacity of trapping a "volume" of contaminants. The bypass filter that you have is not designed to trap and hold any contaminants.When the quantity of contaminates cover the surface of the filter to the degree that the pressure differential overcomes spring pressure-- it bypasses.
The reg 23.971 talks about a quantity that the sediment bowl (gascolator) is able to hold. Is that important? I think so.
I mentioned that I had seen water and even mud in gascolator's in my years of flying experience. These cases were mostly all around ferry flights where airplanes had been stored for long periods due to death/incapacitation of the owner etc. etc.. Some of these airplanes were stored outside for a while. After shaking the wings-- draining the sumps until clear, I still was thankful for a sediment bowl to trap the remaining contaminated contents.
Your comment about observing "43 gal per hour to 42" and noting that change as a indicator that the filter is becoming plugged, is not practical in my opinion.. Variations in altitude, temperature, rpm and manifold pressure and indicators would make this impractical.
The engine-driven fuel pump will compensate (up to a point) for the partial plugging of a filter up stream-- and therefore mask that restriction.
You're right, that it is one of those "personal decisions", (isn't amateur building great!). However, "not so good left over's from a long time ago" is not true, in my judgement. And the noose is tightening with the requirement of insurance inspections, and one of the issues that they are extremely concerned about is "modifications" such as this.