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Bill's Glasair Odyssey
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Date:  12-5-2009
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Wing Tank Pressure Test!

I set up a manometer using 3/8 inch ID plastic tubing. The tubing was attached to the sump fuel feed fitting using a hardware store barb fitting. Everthing else was plugged off. I used lung power to pressurize the tank through a tee and ball valve in the 3/8 inch tubing.

I ended up getting 34.5 inches of water (1.25 PSI) on the manometer using lung power. This pressure held tight for many hours.

That is the short story! I had numerous leaks in the test setup. First, I had a plastic plug in the fuel quick drain fitting in the sump - leak. Second I had a wooden close out plate on the standpipe mounting ring with a cork gasket. The wood was 1/4 inch ply, leak. The wood was not stiff enough to get a good seal with the cork gasket. I replaced the plastic plug with an actual drain plug and replaced the wood cover with the standpipe. With all that fixed I then noticed my attempts to tape off the fuel caps also leaked. The manuals say to use wide tape. The widest that I had was 2 inch. I had to use multiple pieces to cover the cap. This set up leaked at the tape seams. I went to Lowes in search of wide tape. No joy. Here is what worked great, Shelf Paper! I cut ten inch squares and centered them over the caps.

With all that done my tank is tight as a drum. The 34.5 inches of water does not budge for four hours. Success.

My advice is to be patient, don't skimp on the test setup pieces (I have about $30 in mine) and do not expect regular tape to work unless it is four or more inches wide. Shelf Paper, cheap and effective. Also suspect your test setup first, wing second. My shop is climate controlled, if yours is not remember change in temperature will affect your readings, the manometer is a very fine measurement of pressure.

After the pressure test I added two ply patches over the LE corners of the wing tip nose ribs over the cabosil fillets I put in yesterday.
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Fuel Sump With Test Hose Installed on Fuel Fitting Area

Fuel Sump With Test Hose Installed on Fuel Fitting Area

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LH Wing Tip Nose Rib - Cabosil Fillet With Two Ply Patch

LH Wing Tip Nose Rib - Cabosil Fillet With Two Ply Patch

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