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Kupe's Zodiac 650B
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Date:  8-31-2013
Number of Hours:  1.50
Manual Reference:  6-K-1
Brief Description:  Install Fuel Senders (Left & Right)

Grabbed my drill, a piece of scrap 6061 skin, a ruler, a marking pen, and both fuel tanks and headed into the basement with them - today I drill the fuel sender holes into the sides of the two fuel tanks.

Step one was to practice using the flycutter. Starting with the scrap aluminum skin, I carefully measured the flycutter blade to be 29mm wide for a 58mm hole (specs call for 59mm, but I wanted to leave room for "growth). I clamped the skin tightly to the workbench, drilled a practice pilot hole and went after it with the flycutter attachment.Turns out not to be that hard to do. Of similar challenge was getting the fuel sender attached through the hole to the skin. Image one shows the scrap skin with the fuel sender attached. works fine.

So the real test is making the same cut into the fuel tank. Using the measurements I made previously to bend the fuel sender float arm into the correct shape, I drilled a pilot hole in the endboard end of each tank and went after it with the flycutter. Image 2 shows the finished hole in the left tank. Mission accomplished. Image three shows the fuel sender installedin the right tank. Both tank fuel senders installed.

After all the drilling and cutting, I wanted to clean out the tanks with some water. Since I was going fill the tank anyway, I thought this was a good opportunity for a gauge check. The following video shows the left tank being filled out back with the ohmmeter attached and the resistance decreasing as the tank fills. Works great and no leaks!


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The fuel sender attached to a practice piece of scrap skin.

The fuel sender attached to a practice piece of scrap skin.

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The sender hole cut out of the left tank. Note the rib hole circle (in blue) for orientation.

The sender hole cut out of the left tank. Note the rib hole circle (in blue) for orientation.

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The finished right tank fuel sender.

The finished right tank fuel sender.

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