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George Henson's Web Site
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Date: 3-5-2008
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Number of Hours: 8.00
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Manual Reference:
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Brief Description: AE Fuel Guardian Sensor Install
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I went out to the flying club to see if they had a couple nuts to install the AE Fuel Guardian sensors in the tank. Dennis, the club's chief mechanic suggested instead of the nut, in order to facilitate any future maintenance on this item, to use a thick chunk of aluminum and tap it for the sensor thread as a mounting block. Turned out that the thread for the sensor is a 12mm x 1.00 and I had to purchase the tap as no one I knew had one to borrow. Dennis was able to supply not only the aluminum, but also self sealing blind rivets, the only problem, the rivets were a little on the short side. His suggestion was to deepen the countersink to allow for the shorter rivet. I also modified an older pop rivet tool in order to press firmly on the deepened rivet holes.
I blocked up one of the fuel tanks to the approximate angle of level flight and mounted dihedral, then added 20 litres (approx 5 US gallons) of water. In order to see the water in the attached hydrometer better, I had added some green food coloring to the water. I marked a vertical centerline in the circular rib stiffener. I then marked the level of the water in the hydrometer and carefully measure the location of the mark and transfered that to the second fuel tank.
After fabricating and tapping the sensor mounting blocks, I matched drilled there location on the tanks. I also opened up the center hole on the tanks for the sensor. I prosealed and riveted the mounts to the tanks, installed the sensors and added plenty of proseal around everything to ensure no leaks.
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Aprox 5 US Gallons
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Sensor mounting blocks
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Seinsors installed and prosealed.
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