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Re: (21) Fuel Tank ( Mike)

PostPosted: Thu Jan 06, 2011 8:11 pm
by planecrazzzy
Hey Guys,
Now that I can tighten the tank in place , I can locate the hole in the windshield....

I rolled some material on my 3 in 1 tool and made a tube custom fit to the fuel flange...

Then , I welded a flat plate on it and cut the excess and made a flange to match it...

At First , I wanted the Fuel Filler unit to be as low as possible ... ( For Vision purposes )

Most Tailwind pictures I have seen , have a rubber hose clamped on the Fill spout....

I didn't want to make mine "two" pieces"... So I ground my filler spout and put duct tape on it to hold it "in place"....

Then , I tried to remove the tank....No Joy.... The filler needed to be raised , in order to clear the tube...

So, I needed to shim the filler tube...and move it higher on the windshield ( Not Much )

Again I taped it in place.... This time I was able to remove the tank without moving the Filler tube...

I tacked it "in place"... a GOOD tack...

I put the tank back in it's place and strapped it... looks good...

I took it out... Put another GOOD tack 180 degrees from the other one... and installed the tank again...

Still good.... I welded it up...

I needed to bang it around a little after finish welding.... but it looks good now.

I'm VERY happy with the way it turned out.
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Here's the pictures...
Gotta Fly...
Mike & "Jaz" in MN
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Re: (21) Fuel Tank ( Mike)

PostPosted: Thu Jan 06, 2011 8:17 pm
by planecrazzzy
Hey Guys,
Another thing... I made some temporary blocks to hold the tank center...

This way , when I check "fit"... it keeps going in the same position...

Notice on Fit up check... The straps are tightened like normal...
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Gotta Fly...
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Re: (21) Fuel Tank ( Mike)

PostPosted: Thu Jan 06, 2011 8:20 pm
by planecrazzzy
Hey Guys,
Here's how it turned out...

I've used the filler tube to mark the windshield... I'm ready to cut the hole.
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Gotta Fly...
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Re: (21) Fuel Tank ( Mike)

PostPosted: Fri Jan 07, 2011 9:54 pm
by planecrazzzy
Hey Guys,
I double checked with the Tailwind guys about the Tank Vent...

Jim C suggests High on the Filler tube.... Good enough for me.

I found some material that was thick enough... Drilled a Hole and Tapped it ( 1/4 - 18 pipe thread )

With the tank in place , I checked the fit for the vent hole.
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Gotta Fly...
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Re: (21) Fuel Tank ( Mike)

PostPosted: Fri Jan 07, 2011 10:03 pm
by planecrazzzy
Hey Guys,
I'm mounting my Flush Fuel Cap....

I'm using 8-32 inserts... they worked pretty good...

I'll need a cork gasket... the inserts leave raised bumps , I don't want to grind them.

DJD found the Flush Fuel Cap for me in the ACS catalog... it was only around $35 bucks...
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I like how it looks , and it didn't cost me an Arm and a Leg...
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Gotta Fly...
Mike & "Jaz" in MN
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PS I made a Gasket out of a heavy welding glove...I used the leather from the forearm area...
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Re: (21) Fuel Tank ( Mike)

PostPosted: Tue Jan 18, 2011 11:24 am
by planecrazzzy
Hey Guys,
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Building is an "Art".... Time for a little "Bling"

This design ( Engine Turning ) Helps hide scratches.... But I think it just looks cool...

and "Fairly" easy to do...

I'm using a 2" scuff pad on a 90 degree Die Grinder

First , I wipe it down with Lacquer Thinner , this helps the sharpie marker "stick" good.

I mark every 1.125" , both directions.... This makes the square slightly bigger than my scuff pad...

otherwise I would "rub out" the lines I need...

I usually go from right to left... it doesn't matter , but they need to be the same through out the pattern...

I dip the scuff pad in WD-40 every few swirls... it cleans the pad and slows down it's "wear"
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Here's some pictures...
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Gotta Fly...
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Re: (21) Fuel Tank ( Mike)

PostPosted: Tue Jan 18, 2011 11:27 am
by planecrazzzy
More Pix

Re: (21) Fuel Tank ( Mike)

PostPosted: Tue Jan 18, 2011 11:38 am
by planecrazzzy
Hey Guys,
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If you need to "Bondo" spots on your tank , This design will still work.

I'm sure it would still look nice after painting.
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Gotta Fly...
Mike & "Jaz" the Flying Dog
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PS Doing this stuff on a "Curve" surface is different and harder than a Flat Surface... But not bad....
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Re: (21) Fuel Tank ( Mike)

PostPosted: Sat Feb 05, 2011 9:37 pm
by planecrazzzy
Hey Guys,
Here's the Fuel tank "in place"

With the Rubber on the straps , and the Fuel Filler screwed into the Windshield
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Gotta Fly...
Mike & "Jaz" in MN
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Re: (21) Fuel Tank ( Mike)

PostPosted: Mon May 27, 2013 7:06 am
by stewarmo
Hi Mike, can you please tell me the name of your 3 in 1 machine? It looks like a useful tool and your work is amazing! Thanks.
Stewart

Re: (21) Fuel Tank ( Mike)

PostPosted: Mon May 27, 2013 4:54 pm
by planecrazzzy
Hi Stewart,
I'm not really sure of the "Brand Name".... It was from Northern Tool

it is the 40 inch model....

It was modified somewhat.... But not much...

The 40" cost twice as much as the 30" model.... But the 40" is needed to do the job...
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Gotta Fly...
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stewarmo wrote:Hi Mike, can you please tell me the name of your 3 in 1 machine? It looks like a useful tool and your work is amazing! Thanks.
Stewart

Re: (21) Fuel Tank ( Mike)

PostPosted: Thu Jan 09, 2014 10:43 pm
by SheepdogRD
stewarmo wrote:Hi Mike, can you please tell me the name of your 3 in 1 machine?

planecrazzzy wrote:... I'm not really sure of the "Brand Name".... It was from Northern Tool

it is the 40 inch model....

It was modified somewhat.... But not much...


How did you modify the shear/brake/roller?

And what bead roller and roller dies are you using? Is it manual, or powered?

Thanks . . .

Re: (21) Fuel Tank ( Mike)

PostPosted: Thu Jan 09, 2014 11:12 pm
by planecrazzzy

How did you modify the shear/brake/roller?

And what bead roller and roller dies are you using? Is it manual, or powered?


OK... Mods on the 3 in 1 tool...
Made the "Cart" to roll it around , Used shopping cart wheels.
Also made two adjustable legs to secure the cart during heavy use.
Made another handle for the opposite side.
Modified the Handle "Holding Slots" with aluminum spacers to give better "Clearance".
With a small grinder... I carefully made the slots at the end of the rollers "Bigger" for 3/8" tubes.
a better "Backstop" for the Brake, from cold rolled steel... goes right up to the lower die.
Made a full length upper brake die... made it the same size as the "Pan Fingers" for easy switch.
I have three pieces of 1/4 cold roll that lay in the lower Brake to make SMALL bends, tiny lips.
Had to re adjust my shear blade... Factory has a habit of TIGHTENING the adjusting screw...
Put heavier springs in the shear "Hold Down" bar...
Made a "Catch tray" for drops...

The Beader is "Woodward Fab" , through Northern Tool.... Standard die rollers came with it
I think about 6 sets.... This has been a cool tool...
This is manual ...
But I modified it and it's easier to control the piece using a wheel instead of the crank.
I also made a gear "Guard" , and a "Tab" for using it in a Vise.
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The One other tool I use with these... English Wheel , Mods needed there too...
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Gotta Fly...
Mike & "Jaz" the Flying Dogz

PS Look in the "Tool " area on this site...http://www.wingsforum.com/viewforum.php?f=325
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Re: (21) Fuel Tank ( Mike)

PostPosted: Sun Feb 02, 2014 1:58 pm
by flw
Mike,

I am getting ready to build my tank for my Buttercup. I found your logs very helpful, thanks. I have two questions.

1. what diameter is the filler tube?
2. it appears that you welded the filler tube to the tank prior to cutting the hole in the tank. If that is accurate, how did you eventually cut the hole in the tank, and since the tank was completely welded, didn't you worry about metal shavings?

Thanks,
Fred

Re: (21) Fuel Tank ( Mike)

PostPosted: Sun Feb 02, 2014 9:03 pm
by planecrazzzy
First, I built the filler tube to "fit" the fuel cap...Custom fit...

I did put the hole in the Tank first... But I'm sure I bounced a die grinder

on it to clean it up after welding... This was the least of my worries...

Later... during "Panel" construction... My Transponder needed more room...

After my pressure test... I had to cut into the tank AGAIN...

I cut a big hole... and welded it back up with an area for the transponder...

Basically.... Blow out what you can with AIR.... bang it... more AIR...

Finally... I rinsed it with water...and a few Stainless Steel ball bearings...

Gently swish it around...and dump until clean.

I didn't really have "Shavings".... more like grinding dust...

Gotta Fly...
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