The mount was another headache. I went through 2.5 designs before ending up with what you see in the pictures. It consists of 3 separate pieces cut from .063 6061-T6, cut on the table saw and bent on the metal brake. Some lightening holes were added using the hydraulic knock out and flared using some custom dimple dies I made for a previous project. Nut plates were added so that all 3 sections can come apart. It works by clamping onto the existing 5/8" square tubing structure. HVAC clamps hold the bottle to the bracket. In case you are wondering if it is sturdy or not, you bet. The hands of hercules could not move that bottle from its location.
At the top of the tank there is 1/8" clearance between the engine receiver mount and header tank. On the bottom of the tank there is 1/2" clearance between the flaps pushrod. In case you are wondering about whether the tank leaks or not, I filled it with water and left it sit for several hours, no moisture present. If for some reason I do find a leak, I will replace the PTFE washers with viton o-rings.
From a safety perspective, this one gallon is enough fuel to provide takeoff and reach about 400 feet before running out. This is important in case the transfer pump that moves fuel from the wings to the header tank failed during take off. At 400 feet you can do a simulated rope brake maneuver and land downwind.
