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Jerrys Web Site
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Date: 1-28-2012
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Tank and Skin Installation
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Today, I tried the balloon test on my almost completed right wing and couldn’t get the balloon to stay inflated. I pretty well isolated the problem to the bottom corner near the fuel filler cap, in the first bay outside the tank (top wing skin is still removed) near the spar. I added approximately 10 gal of water to the tank, and yes, found water seeping out between the wing/leading edge skin and the bottom spar flange in the first bay outside the tank. Next, I took my air gun and put it next to the wing skin and spar flange while looking through the filler cap with a flashlight. I had bubbles in four locations along the spar/bottom tank skin mating area in the first bay. The last set of bubbles was next to the first rib over, so I have to assume I have a leak in the next bay over as well. For some reason, I must not have good adherence between the tank skin and the spar flange. Before assembly, I cleaned and scotchbrited everything with good cross hatching etc. Perhaps I had an area such as the spar flange that never got sufficiently cleaned or something. Don’t know. I trusted the proseal, and there was an approximate 1/8” bead evenly across the flange where it flowed out during riveting – perhaps too much squeezed out? I didn’t filet it up any more than that. I did cover the rivet tails.
So, after asking the Rebel Forum for suggestions, I believe I'll let it dry for several days, then try vacuuming some Proseal Type A2 (more liquid than regular Type B2) into the leak area, then build up a good fillet on the inside.
In the meantime, I pulled the access panel cover in the fourth bay where I know I have the problem This was not easy as the proseal had cured. I used a small 1/4" wood chisel to lift an edge, then used it to pry the cover loose. Now I'll just have to wait for the tank to dry etc.
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