Fuel tank leak fix thread

cjensen · Post by **cjensen** » Sat Oct 23, 2010 3:11 pm

I don't have a lot of time right now, but I'll throw out some pics from this morning's tank removal...thankfully it rained all morning!

Here are a couple of pics of the leaking areas...the bottom-

...and the top where the red hash marks are-

Tank bolts removed...this was a PAIN IN THE ASS. It sucked. Period.

Staining on the spar-

The leak on the TOP of the tank, extends between the red arrows-

This was interesting to find, but not terribly unexpected with SW float senders...it has a small leak at the sender screw itself. Not a whole lot I can do about that unless I replace it-

Sad pic...

So tomorrow I plan to cut holes in the rear baffle...

It's not as bad as I was expecting to see, but now I am TOTALLY dreading putting those tank bolts back in when I'm done.

Gotta run...more later!

Post by **Spike** » Sat Oct 23, 2010 3:47 pm

Woooow dude. This is my biggest fear. I fought my tanks, one of them especially.

Please make sure you vent that tank thoroughly before exposing it to any tools that could act as an ignition source.

Spike

Sent via DROID on Verizon Wireless

-----Original message-----

From: RB Lists - Screwup Chronicles <support@rivetbangers.com>
To: screwup@rivetbangers.com
Sent: Sat, Oct 23, 2010 20:11:38 GMT+00:00
Subject: Fuel tank leak fix thread

I don't have a lot of time right now, but I'll throw out some pics from this morning's tank removal...thankfully it rained all morning! Here are a couple of pics of the leaking areas...the bottom- ...and the top where the red hash marks are- Tank bolts removed...this was a PAIN IN THE ASS. It sucked. Period. Staining on the spar- The leak on the TOP of the tank, extends between the red arrows- This was interesting to find, but not terribly unexpected with SW float senders...it has a small leak at the sender screw itself. Not a whole lot I can do about that unless I replace it- Sad pic... So tomorrow I plan to cut holes in the rear baffle... It's not as bad as I was expecting to see, but now I am TOTALLY dreading putting those tank bolts back in when I'm done. Gotta run...more later!Chad Jensen N755CB|RV-7|Flying RV-7 Build Log rivetbangers.com - Discussion topic http://www.rivetbangers.com/forums/viewtopic.php?p=35315#35315

Submitted via email

cjensen · Post by **cjensen** » Sat Oct 23, 2010 8:46 pm

Air tools only...shop rule at work (where I'll be working on it) when working with fuel tanks...

cjensen · Post by **cjensen** » Sun Oct 24, 2010 2:29 pm

Today was cutting day...but first, I started by removing the inspection panel on the inboard rib by taking out the screws, giving a good slice thru the sealant with a knife, and it popped right off...

Then it was time. Time to use everyone's favorite tool...the fly cutter. I have to say that I was quite pleased with how this worked out. I was dreading it because of the fly cutter's reputation for grabbing stuff and flinging it across rooms. This was a breeze actually...other than needing ear plugs to mute the squeal of the cutter.

Three holes cut at 5" and one at 3.75" all cleaned up.

I took a few pictures of the "bead" that was there from when I built the tanks. I actually didn't think it would look as good as it did, but it obviously wasn't good enough. One pic is good enough to show what each bay looked like.

From what I've read, almost everyone says to keep the working hole as small as possible...why? I don't know...less surface area to reseal later? Anyway, it was gonna be hard enough/messy enough as it was, so my larger 5" holes aided in maneuverability to get the sealant spread. It's still a mess in there, but the fillet is nice and smooth on the top and bottom...

And then the thread had to be ruined by some crazy dude peaking thru a hole at you...

I'll let that setup until tomorrow night, and then check things over. I may put a small amount of fuel in the tank and tip it so it doesn't spill out of the working holes to check for leaks along the baffle seam before I seal the patch covers in place.

Post by **Spike** » Mon Oct 25, 2010 12:37 pm

Thanx for the pics. How do you plan on plugging those holes in the back? Are you going to do a similar design as the fuel sender panel?

Spike

cjensen · Post by **cjensen** » Mon Oct 25, 2010 1:28 pm

Yep, it'll end up looking just like this...

Post by **Spike** » Tue Oct 26, 2010 7:48 am

Nice. Blind rivets or screws for those panels?

Spike

cjensen · Post by **cjensen** » Tue Oct 26, 2010 7:56 am

Screws...they'll be done just like the side access panel. I just ordered the panels and gaskets from the web store. I'll have to make a panel and gasket for the smaller hole tho...

cjensen · Post by **cjensen** » Wed Oct 27, 2010 6:10 pm

I'll know more in the morning...

hydroguy2 · Post by **hydroguy2** » Wed Oct 27, 2010 6:32 pm

good luck.

put some papertowel or white sheet under it. IF...fingers crossed it doesn't, but IF you have a leak you'll be able to track it down better.

cjensen · Post by **cjensen** » Wed Oct 27, 2010 6:37 pm

Great idea...unfortunately, I'm already home, plopped on the couch watching the Series!! Just hoping for the best!

captain_john · Post by **captain_john** » Wed Oct 27, 2010 6:54 pm

Keep in mind, you will have a fair amount of evaporation overnight.

It's amazing how fast 100LL evaporates!

CJ

cjensen · Post by **cjensen** » Wed Oct 27, 2010 7:08 pm

Yeah, the guys told me to expect it to be 1/4-1/2" down by morning.

What a waste of good <expensive> fuel this is...

cjensen · Post by **cjensen** » Wed Nov 03, 2010 7:33 am

Finally had some time to get back to the tank last night. I didn't quite get to sealing the covers, but the plate nuts are in, and I plan to have my own private sealant party tonight...

hydroguy2 · Post by **hydroguy2** » Wed Nov 03, 2010 12:41 pm

Party? by yourself? you're an animal

cjensen · Post by **cjensen** » Wed Nov 03, 2010 12:42 pm

hydroguy2 wrote:Party? by yourself? you're an animal

I know! It's gonna be SO fun!

cjensen · Post by **cjensen** » Wed Nov 03, 2010 7:46 pm

My party is over...but the good news is, the sealant is on and curing!

Prayer beads are out...hoping for the best for an overnight test tomorrow!

Man I hope to be flying again this weekend!

Post by **Spike** » Thu Nov 04, 2010 8:03 am

Good news Chad. Let us know know how the test goes. I hope I don't have to go through this.

Spike

cjensen · Post by **cjensen** » Thu Nov 04, 2010 8:35 am

For your sake, I hope you don't either! I hope I'm done with this!!

'Course, if it doesn't leak, I have to plan on a half day of swearing at the tank to get it reinstalled...not looking forward to THAT!

cjensen · Post by **cjensen** » Fri Nov 05, 2010 12:24 pm

The tank has been holding fuel since 9am this morning...fingers still crossed, but it's looking pretty good!