Trusting my EZ foam and fiberglass construction skills far more than sheetmetal (plus this is a complex shape) I'm making the tank shell using 3/8" PVC foam. I'm using the exact same construction and layup methods used in the Long-EZ fuel tanks. Unfortunately I didn't have enough epoxy here to get as far as I hoped.... but it's a start.
Later discovered my 25 yr old epoxy pump wasn't putting out enough hardner in the mix, so it didn't set up.... had to pull all the glass work off the foam and clean up the foam. Now have to order more foam and waiting arrivial of more epoxy. After putting the epoxy pp in a "warming box", the darn thing is now working fine..... Ummm.... guess it's "been a while"...
Tank parts layout on foam sheet
Tank parts trial fitted together
Inside surface glass layups. Note use of peel ply along edges.
