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Ron's Web Site
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Date: 3-14-2010
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Fuel Tank Welding 2
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I prepared the fuel tanks for welding. I trimmed the fuel necks down to the median needed height using first a Sawzall, followed by a 4 inch electric grinder, followed by an 80 grit right angle die grinder followed by a vixen file to the median height. I then reinstalled the tanks, including fuel nipples, and determined what amount of additional tirmming was needed. In the case of the aux tank, there was no more of the original filler neck to remove, so I used the lathe to remove the chamfer, which allowed the filler neck insert to sit down in the hole better. Additional triming was undertaken on the main tank. I shortened the filler neck insert on the main, as the residual filler neck supports the new filler neck insert. On the aux tank, I kept most of the filler neck insert length, but drilled 3 holes to allow full filling of the tank.
I then used a hole saw to cutout the fuel tank sender holes in the appropriate locations, and drilled and tapped them. I had trouble on the other wing with heat causing melting of the thin upper rim on the aux tank, and I made a copper heat sink which will hopefully avoid that problem on the left wing tanks.
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Trimming main fuel filler neck insert.
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Trimmed insert and tank and copper heat sink.
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Tapping fuel sender flange.
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