|
|
|
|
Ron's Web Site
|
Date: 11-15-2009
|
Number of Hours: 8.00
|
Manual Reference:
|
Brief Description: Aux Fuel Tank Filler Neck and Welding 1
|
|
After I almost finalized the aux fuel tank position, I used the inverted hole saw trick to mark the fuel tank filler neck position, and used a knockout punch to cut the 2 inch hole in the upper wing skin. I then placed the fuel tank cap sleeve into the existing neck and measured the height of the filler sleeve above the wing skin. As can be seen in Image 1, the neck and sleeve were considerably above the wing skin. Since the sleeve could only account for 0,4 inches of the height above the skin, you can see that the standard filler neck will rise about a 1/4 inch or more above the skin unless it is trimmed down. I ended up using a Dremel-type cutoff tool and hacksaw blade to cut the neck, followed by sanding to get the height down to that needed for the Aero fuel filler cap. I drilled three each 3/8 inch holes in the sleeve so that the tank will be fully filled. After that, I TIG welded the fuel vent, fuel sender flange, fuel filler neck, and grounding lug. The fuel filler sleeve turned out to be very difficult as the sleeve tapers down to a very thin upper rim, which easily melts. I ended up with about 4 "melts", which don't interfere with the fuel cap operation and minimally visible with the cap in place, but nonetheless are annoying. I tried using a #5 cup instead of the #7 I usually use, but that ended up with too much heat for the cup, which started melting and contaminating the weld. Ultimately, I ended up doing best with the cup coming almost horizontal to the weld line with occasional tips toward the tank to move the puddle there.
|
|
Height of fuel filler sleeve above wing skin.
|
|
Fuel filler neck and sleeve after trimming and drilling.
|
|
Fuel vent flange welded with bloopers.
|
|
|
|
|
|
|
|
|
Copyright © 2001-2024 Matronics. All Rights Reserved.
|
