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Debo Cox - Zodiac 601 XL
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Date:  1-12-2007
Number of Hours:  1.00
Manual Reference:  6K
Brief Description:  Wing Tank Form Blocks

Well, I'm back in the saddle. After taking a much needed break, I began work again tonight on N161DR. I had sawed out the rough blanks of my wing tank form blocks a few weeks ago, but finally sanded them to their finished dimension, and sanded the 10 degree setback for bending the flanges. I'm making a small departure from the plans on my tanks. The plans call for having them welded, but I've heard of problems with welded tanks cracking and the like, so I'm going to make my own riveted tanks sealed with Proseal. It's not a totally new idea - Dave Clay and others have done it with good results. My plan is to make the tank ends (and an internal baffle) in much the same way that wing ribs are made. Where bends are too tight - like the nose of the tank, I'll drill a relief hole and cut the flange. The whole thing will be sealed with Proseal, so a perfect fit isn't necessary, but I'll be able to get very close. I've already ordered all of the necessary fittings, rivets, and fuel senders so I'm all ready to go. Tomorrow I'll make the tank ends and baffles and try to get the tank skins cut. We'll see how it goes. Feels good to be cranking up again.
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Blocks screwed together for identical sawing

Blocks screwed together for identical sawing

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Blocks finished

Blocks finished

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10 degree setback detail

10 degree setback detail

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