Apr 16, 2024     Aerospace Systems Fuel boost system       Category: Fuel System

I received my Fuel Pump Control Module (FPCM) from Aerospace Systems and have been working to install it. I have had to make some minor modifications but nothing too drastic. My previously complete fuel lines no longer work so I had to make some new ones but this time around it was a lot easier as the tubes are now longer so they are easier to manipulate. Also one of the feed lines from my long range tank was too long and interfered with the boost pump. To fix it I had to drill out a rib so that I could get the necessary tooling in there to shorter, bend and flare the line.

Another change was that I needed a different power wire (more amps) from the VPX. The previous setup was one pump and now there are two and the FPCM module. All together I needed a 7.5 Amp breaker. The two boost pumps in the wing each require a power wire run but luckily I had an extra wire already run and was able to utilize that wire so that was fortunate. Now I am working to secure wiring from the wing root to the pumps themselves. I had to make a bracket but I think I found an acceptable solution.

I also finally received the correct diameter metal tube for the brake reservoir and made that line. Its almost comical that I had to wait a couple months for the tube to make a 3 inch line.

Lastly, a lot of big things are about to happen: My MT prop and RS flight systems controller should be arriving any day now, I am going to Rotax engine training next week for the servicing and maintenance courses, and my Firewall Forward Kit was just crated and should be shipping soon.

  Jun 01, 2023     Clamping the fuel lines in       Category: Fuel System

This past week I finished clamping in and torquing some of the fuel lines in the fuselage. Making the lines was one task and getting them clamped was another in itself, not hard just a pain. I also finished the aux tank to transfer pump fuel line connections, of couse i made a big mistake and cut he fuel line to short. I forgot how much room i would need with the flare tool and the fuel line connections. As a result I had to make a new fuel line and get into some tight spaces in the wing root area.

  May 12, 2023     Long range tank pumps       Category: Fuel System

After some deliberation I settled on the exact pump I wanted and also how I wanted to transfer fuel from the long range tanks to the main tanks. I am deviating from the plans but it does not make sense to me to bring the fuel from the LR tanks into the fusalage center console to redirect it back out to the mains. Its more complexity, material and valves. I also opted to not use the provided rubber fuel lines which need to be changed every five years and I am fabricating metal fuel lines which will be good for life.

  Dec 21, 2022     Left Wing and Tank done, Fuselage started       Category: Fuel System

I fixed the aux tank mount problem by drilling the nut plates, elongating the holes for the bolts then drilling and countersinking new holes for the nutplates. Problem solved. With the tanks mounted next was riveting the top skin on. Luckily for me my mother and step father were in town for the holidays so I put them to work. It took us about two days but we finished the left wing and moved it over to the rack.

I also started putting the rear fuselage together which went a lot quicker than expected once the ribs were all built. Currently I am only able to install the lower aft fuselage skins because sling sent me the parachute version and I ordered the non-parachute.

  Dec 09, 2022     Left Wing Aux Tank Install       Category: Fuel System

So I finished leak checking the left wing auxiliary tank and no leaks. I went to install it on the wing and all the clecos line up and both mount ends bolt in. For some reason the middle mount is off. I double and triple checked the instructions and I am confident it is assembled correctly. I didnt have this problem on the right wing. I will reach out to technical support for further guidance. Right now I am thinking I will remove the nut plates on the middle mount, elongate the holes, drill new holes for the rivets to hold the nut plates and I think that will work. I'll let you know what I come up with.

  Oct 25, 2022     Rt Main fuel tank install, Lt Main tank leak test       Category: Fuel System

Now that the aux tank is installed and the top skin it was time to install the Rt Main fuel tank. The only little thing here is that it was a tight fit for the fuel line from the aux tank behind the main tank. Yes that line was wrapped in foam tape but some of the main tank brackets were pressing into the foam a little more than I wanted to I also put some plastic wire conduit around the foam for a little protection. Other than that the tank went on without a hitch. After that I tapped or caped all the fittings or holes so I wouldnt get any bugs making homes.

After that I leak tested my Lt Main tank and I found my first leak. I slightly pressurized the tank and sprayed the tank with soapy water and thats how I found the leak. Luckily it was a pin hole size leak, unfortunately there was no was I could get to it from the inside. So I mixed up some B2 sealant and dabbed it on the leak from the outside and let it cure for a couple days. I leak checked again and pressure held for 24 hours.

After that I finished what I could on the Lt aux tank but I am still waiting on two fuel lines from the factory so I cant finish the tank or install it which is holding up the rest of the build.

  Oct 23, 2022     All fuel tanks       Category: Fuel System

The right main fuel tank is done and pressure tested, the right auxiliary tank i finished and pressure tested yesterday and bolted it onto the right wing spar today. So far, fingers crossed, I have not had to fix any leaks on the tanks. The vent line on the auxiliary tank was leaking but the flare from the factory was not good so I touched it up with my flare tool and it is now sealed.
The biggest surprise I have had so far is that, last week me Tech counselor swung by and advised me to plug all of my tubing and holes to the tanks. This week I found where a mud dobber completely plugged the fuel feed line for the aux tank. Luckily I noticed it and was able to take it out and clean it up.
My left main tank is also complete but I am letting the sealant cure for another day before I pressure test it. I have been using a piece of tubing as a manometer to build pressure and test for leaks. Interestingly the fuel level sender on the left tank matches exactly what the manual says it should be. I build it the same way as the right wing but I did not get the same results with the right. I contacted technical support and was told that it should work anyway as the delta between empty and full is plenty.

Lastly I am still not able to finish my left aux tank as I am waiting for two more pieces of fuel tubings/fittings to install before I can close it up. One of the pieces is internal to the tank and I just cant do anymore with it. Unfortunately that also means I cant install the top skin, main tank or wing tip because of that.

This coming week I will install the top skin on the right tank and hopefully install the wing tip. But to do the wing tip I will have to take the wing off the factory jigs so I will have to make something to store the wings.

  Oct 16, 2022     Rt Main fuel tank complete       Category: Fuel System

The fuel sender Ohms readings from last week are fine per Sling Technical.

This past week I finished putting the back of the main fuel tank on. It took a lot longer than expected and I would not have finished without my wife's help so a big shout out to Sayo. I let the tank sit for a few days and then did a leak check with a ballon and then a homemade manometer for about a day. I am happy to report there are no leaks.

After that I started working on the landing lights, I worked more on the lens and the lens frame, painted the surrounding area black. I ordered and installed some electrical connectors. I had to decide what kind of connectors I was going to use and ended up deciding to use the same connectors that Midwest Builders uses.

I also started mounting the control box for the GAP26 pitot probe and had to order some connectors for that.

Lastly I went to go and bend some fuel line for the right side extended range tank and it turns out the fuel line bender I had didnt fit the line so I had to order a bigger fuel line bender. Once the bender came in i started bending away and you can see in the pictures, I think it came out pretty good.

  Oct 08, 2022     Fuel tank senders and lights/ first part destroyed       Category: Fuel System

Last week I noted that the fuel level sender did not fit correctly per the plans. After some back and forth with Sling Technical I found out that they updated some parts and I have the old parts. The old plans have different measurements and angles to bend the float arm than the new plans. They said my options were to modify the bracket that is attached to the plate or to re bend the float arms. I wasn't comfortable re bending the float arms because it is a big bend and I dont want to work harden or snap the float arm. Modifying the bracket wasnt much work and I have a working fuel sender. My only question now is the the Ohm readings at full and empty are acceptable as they dont match what thew plans say they should be. Ill just ask technical and see what they say.

I also started working on installing the landing and taxi lights in the extended range tanks and I also started trying to fit the light lens in the wing. Others have noted that it is a pain and I would agree. Of note I started bending the backing plate for the light lense before I deburred the part or prepped it. When I realized I took it over to the debur wheel and started. Well short story, shorter with ther part bent in the shape of the leading edge of the wing i made a mistake and allowed the part to touch the debur wheel at the wrong angle and it ripped the part out of my hands, wrapped around the wheel and was torn into pieces. Luckily I only received a cut on my finger but I will need a new part. I contacted Sling for a new part and they are awesome and a new part is in the mail free of charge.

Last big update is that my fuselage is in the port in California and should be offloaded and ready to ship to me any day now. For the up coming week I will be working on installing the backs of the fuel tanks into place then I will have to do final leak checks after a week or so. I also plan to install the pitot probe tubing and wiring this week.

  Oct 01, 2022     Left Wing tanks       Category: Fuel System

This week was more work on the left wing fuel tanks. I have been doing small jobs such as getting the right size screw to fill some machine holes in the tank ribs and sealing the screws. For some reason the rivets the factory calls for are too small so I had to use 1/4 - 20 screws. I also started leaf testing the right side tanks and I am happy to report no leaks so far. I also started assembling the fuel senders and attaching/ sealing/ bending them per the plans.

One modification I decided to make was to shorten the wire fore the fuel sender. Its an adjustable sender so I had almost a foot of extra wire. It was a very simple process to cut the extra and solder the sorter wire back in place. Towards the end of the week with the sender and plate complete I tried to install it in the fuel tank and it wouldnt fit by a lot so I have sent an email to technical support and will have to let you know how that turns out next week. The float ball contacts the rib so much so that I cant get it to work correctly.

  Sep 02, 2022     Back to building       Category: Fuel System

So I had to take a break from building due to life events. I retired from the military, moved to Dallas, TX, found a new job, bought a house and have been doing a ton of projects related to the house. Now that I have things under control again I am able to get back to building. One of the projects I did was running 220V out to the "airplane factory" so I guess all of the projects werent just for the house. Some of the pictures are from loading the plane up in a UHAUL to transport from florida over to texas and then unloading the plan in its new home. I didnt do much today just installed some rivnuts into the fuel tanks with steel epoxy but, it did feel pretty good working on the plane again.

  Apr 25, 2022     Extened and Main fuel tank right wing       Category: Fuel System

I worked more on finishing up the odds and ends with the main and extended range right fuel tanks. On the main tank I installed and sealed the two end ribs. I also encapsulated the backs of the rivets on the main tank. On the extended range tank, I had a machining hole that the instructions said to fill with a 4.8 rivet, the problem is that rivet even when pulled fits thru the machine hole. I went to home depot and got a 1/4" screw to fill the hole then sealed it. I also installed the fuel pickup line in the extended tank. It may not seem like much but that was a two hour work session.

  Apr 24, 2022     Right Main wing       Category: Fuel System

This weekend I worked on the right main 198 Liter wing tank. A lot of prep work went into it. Last week I sealed the internal fuel tank structure and this weekend I installed and sealed the internal structure to the tank skin. Even with everything test fit, reamed, scuffed up, cleaned, test fir etc. I used almost every minute of the two hour working time of the B2 sealant. This includes a lot of help from my wife, I literally could not have done it without her. I let the tank cure one day while clecoed to the wing spar. Inspecting everything afterwords it looks great and I am very happy with how everything came out. I still need to seal and rivet the two end ribs and am going to add a little extra sealant in some of the corners and also encapsulate the backs of all the rivets for insurance. The tanks are taking a lot more time than I thought. But, I am hopeful that I wont have to be chasing down leaks later.

  Apr 17, 2022     Extened and Main fuel tank right wing       Category: Fuel System

Its been a few weeks as I have been working and also traveling for a job interview. This week was all working on the right wing fuel tanks. I have only done the initial steps and am now waiting on the B2 to cure. I have been using the 3.5 Oz pre mixed tubes but I estimate I will need about 4 more. Several of the sealed pull rivets have malfunctioned and I had to dremel them out. So far I have done two, full two hour sessions with the B2 and I am nowhere close to being done. I am trying not to rush and take my time. I am also taking the time to encapsulate all of the rivet heads on the wet side to help ensure I dont have a leak.

  Apr 03, 2022     Alodine main fuel tanks. Category: Fuel System

No pictures sorry, but some more of the same. I alodined the main fuel tanks. Due to the size of the tanks, about 9 feet long the pieces were awkward to work with but I managed to get all of the pieces done.

  Mar 27, 2022     Fuel tanks       Category: Fuel System

I started prepping the fuel tanks. Since I opted for the long range model I have four tanks to build and decided to start on the small, auxiliary tanks first. Since I cant prime the inside of the fuel tanks I decided to alodine the tanks. Most of the tank pieces were alodined this weekend with the exception of the largest pieces which just wouldnt fit in my crude dunk tank. I will wipe on the coating for the remaining pieces.