Jun 15, 2020     Painted Fuel Tank - (2 hours)       Category: Fuel System

I painted the fuel tank with Rustoleum protective enamel.

  Jun 14, 2020     Primed Fuel tank - (1 hour)       Category: Fuel System

I sprayed the tank with zinc chromate primer.

  Jun 14, 2020     Tested Fuel Tank with Water - (4 hours) Category: Fuel System

I filled the tank with water one gallon at a time, and noted a total capacity of 18 gallons. I drained the tank through the fuel outlet until flow stopped. I then drained all remaining water out through the drain sump, collected and measured it. Sitting still on a table in the straight and level flight attitude, the unusable portion measured 15 and one third cups. I will round the unusable portion to one gallon and use that as the basis for calibrating the fuel gauge. I found there to be no leaks.

  Jun 02, 2020     Attached Fuel Quantity Probe, Filler Cap, and Threaded Flanges - (4 hours)       Category: Fuel System

I installed the fuel quantity probe, fuel filler cap, and the two flanges in the sumps in the bottom of the tank. I used Permatex Form-A-Gasket on the threads of the fuel probe fitting, and the flange and flange adapter of the filler cap. The filler cap is attached using 6-32 stainless steel screws with nylock nuts and stainless split lock washers. The flanges in the sumps are fixed using JB Weld as sealant, and are screwed to the sumps using 6 stainless 4-40 screws.

  Jun 01, 2020     Sealed Rivets - (4 hours)       Category: Fuel System

I brushed thinned JB Weld on the outsides of many of the rivets as an extra seal precaution. I also sloshed and brushed thinned JB Weld on some of the rivets on the inside of the tank.

  Jun 01, 2020     Fuel Quantity Probe - (1 hour)       Category: Fuel System

I received my custom length capacitive fuel probe. It has an NPT fitting to screw into the flange on the top of the tank, and is 8.5 inches in length.

  May 30, 2020     Bondo On Outside of Tank - (4 hours)       Category: Fuel System

I sanded the tank to prepare it for painting. I filled the outsides of the top edges with Bondo to create a smoother appearance. I also coated some of the machine screws inside the tank with JB Weld for sealant.

  May 28, 2020     Assembled Fuel Tank - (6 hours)       Category: Fuel System

I built a cover with plugs for the vent tubes to be used on the ground.

I etched with acid the areas of the fuel tank to be sealed, applied proseal to the seams, and riveted the tank together.

  May 18, 2020     Vent Tubes, Probe Flange - (1 hour)       Category: Fuel System

I split the ends of the vent tubes, and splayed them out in four directions inside the tank. I riveted them in place, and further set them in place and sealed them with JB Weld. I also sealed the inside of the threaded flange area for the quantity probe with JB Weld.

  May 16, 2020     Fuel Probe Mount - (2 hours)       Category: Fuel System

I made a hole in the top of the fuel tank between the vent and the side, and riveted a threaded flange in the hole, to accept the fuel quantity probe later. I filed a subtle curvature into the flange to make it fit the curve of the tank top.

  May 04, 2020     Made Gussets for Fuel Tank Sumps - (6 hours)       Category: Fuel System

I made and riveted four small pieces of aluminum that form gussets to strengthen the attachment of the two sumps in the bottom of the fuel tank. These gussets are in addition to the rivets trough the sides and back of the tank. They attach the sumps to the pieces of aluminum angle running across the bottom of the tank. I also made several measurements of the fuselage to aid in designing the turtle deck.

  May 02, 2020     Riveted Top of Tank - (4 hours)       Category: Fuel System

I riveted the top of the tank, the sides, and the angle pieces into a complete assembly, to be joined with the bottom assembly later. I also riveted the mounting bracket to the top of the inside to form the base for the vent tubes.

  Apr 28, 2020     Steel Fittings, and More Fuel Tank - (5 hours)       Category: Fuel System

I got some of my steel fittings cut at a machine shop using a water jet. They are made from 4130 alloy, .090"" thick. I cleaned these up with the belt sander, sprayed them with gun oil, and packed them away in a heavy plastic bag with my engine block. I also finished forming the top of the tank.

  Apr 27, 2020     Continued Fuel Tank - (5 hours)       Category: Fuel System

I finished the flange adapter, and located it on the top of the tank. I drilled the holes for screws to hold the fuel filler cap, and cut its hole using a router. I located the vent tube mount, and drilled its holes. I also bent and formed the two vent tubes.

  Apr 26, 2020     Fuel Tank - (7 hours)       Category: Fuel System

I reassembled the fuel filler cap, contoured the ring that will form the filler cap flange adapter, and bent the top piece of the fuel tank. I drilled many of the holes required to form the top of the tank.

  Mar 10, 2020     Started Top of Fuel Tank - (3 hours)       Category: Fuel System

I cut a piece of aluminum sheet to form the top of the fuel tank. I bent one end and prepared to drill holes to begin fitting it to the tank.

  Mar 02, 2020     Built Drain and Outlet Tubes - (5 hours)       Category: Fuel System

I routed the holes in the bottom of the fuel tank through the tabs formed by the side pieces to complete the circles, and assembled the tubes that will form the sumps for the drain and the fuel outlet.

  Feb 26, 2020     Attached Flange Adapter to Fuel Filler Flange - (1 hour)       Category: Fuel System

I made a plywood standoff ring and attached the fuel filler flange to the flange adapter. This will allow me to turn the inside diameter of the flange adapter by gripping the flange in the lathe. I have to do this because the chuck on my father's lathe is too small to grip the flange adapter by the outside.

  Feb 25, 2020     Turned Tubes And Fuel Cap Flange Adapter - (4 hours)       Category: Fuel System

I turned sections of aluminum tubing to length, which will form the sumps in the bottom of the tank, and turned the outside of the adapter to fit under the flange of the fuel filler cap, to allow the flat fuel cap to conform to the curved surface of the top of the tank. I drilled and tapped six holes for 6-32 threads to allow me to attach the flange to the flange adapter for turning.

  Feb 24, 2020     Match Drilled Bottom and Sides of Fuel Tank - (5 hours)       Category: Fuel System

I drilled the rivet holes in the large angle pieces, tapped the ones in the ends for 4-40 threads, assembled the tank and match drilled all the holes, fastening it all up with Clekos.

  Feb 22, 2020     Marked Rivet Hole Locations - (1 hour) Category: Fuel System

I centerpunched the rivet hole locations in the two aluminum angle pieces that will form the base of the fuel tank.

  Feb 19, 2020     Continued Fuel Tank - (4.5 hours)       Category: Fuel System

I deburred the holes in the bottom piece, I cut out the other side piece, removed the paper patterns from both side pieces, routed the holes in the bottom piece, and bent the edges of both side pieces.

  Feb 18, 2020     Continued Fuel Tank - (4 hours)       Category: Fuel System

I finished the edges on one side piece, bent the ends of the bottom piece, and drilled rivet holes in the bottom piece. I used lacquer thinner to remove the paper pattern off the bottom piece. It dissolved the glue very cleanly and allowed the paper to slide off easily.

I routed a radius on the edge of my workbench top to form the bends in the bottom piece.

  Feb 17, 2020     Began Fuel Tank Construction - (5 hours)       Category: Fuel System

I glued full size printouts of my fuel tank parts to sheet aluminum, roughly cut out the parts, drilled many of the necessary holes, and fitted the aluminum angle pieces together that make up the support struts on the bottom of the tank.

  Feb 11, 2020     More Fuel Tank Parts and Supplies - (1 hour) Category: Fuel System

I purchased sheet aluminum, aluminum angle, rivets, cleco fasteners and pliers, screws and washers for my fuel tank.

  Nov 27, 2019     More Parts Purchased - (1 hour) Category: Fuel System

I purchased aluminum plates for under the filler cap and under the fuel probe, a piece of aluminum strip to form a base for the vent tubes, and pieces of copper tubing to create vent tubes.

  Nov 21, 2019     More Fuel Tank Parts - (1 hour)       Category: Fuel System

I purchased a drain valve, a second threaded flange, and a fuel filler cap.

  Nov 20, 2019     Fuel Tank Design - (6 hours)       Category: Fuel System

I did some CAD design work on my fuel tank, which I plan to rivet together with sealant rather than having it welded.

  Nov 14, 2019     Fuel Tank Parts - (1 hour)       Category: Fuel System

I purchased a threaded flange, a finger strainer, a piece of aluminum tubing and two pieces of aluminum angle to begin constructing the fuel tank.