(21) Fuel Tank ( Mike)

(21) Fuel Tank ( Mike)

Postby planecrazzzy » Sat Dec 18, 2010 12:06 pm

Hey Guys,
I got a sheet of 5052 - .05 Aluminum.... ( About $60 bucks )

I'm ready to start fitting a tank in this Bird... I'll be extending it larger than the prints show....

It starts with a mark on the Firewall.... I put plywood under my heels.... feet on the rudder pedals...

and with a little clearance... mark the firewall... Now I have one dimension of the tank...

Next , I cut a pattern... and double checked it to my feet...

This was a good start... I have bulged the tank like the Tailwind guys do....

Later , I'll use this template to use the last few inches of material to form the "Upper" extension I'm planning to add...( Jim C's mod )
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Gotta Fly...
Attachments
Fuel Tank.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Fuel Tank

Postby planecrazzzy » Sat Dec 18, 2010 12:22 pm

Hey Guys,
My shear won't cut a stock 4 X 8 sheet... So I gotta whittle off a piece I can handle...

This Nibbler was cheap and works great for this.... it doesn't warp the material...

I usually stand up the sheet on milk crates... clamp my straight edge on ( Pretty tight )

and a drip a little oil in the path being cut....

One hand on the tool and one hand holding the shop vac... I make the cut....
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The shop vac is important to me.... I got one of those little half moons in my foot , in the house....

I don't wanna be tracking THOSE in the house anymore !!!!
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I put a bend in the beginning just for strength....and it will help during welding...
Attachments
Fuel Tank 001.jpg
Fuel Tank 002.jpg
Fuel Tank 003.jpg
In this picture... The pattern is bowed.... it is an outside dimension...
It's just in place for a picture.
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Fuel Tank

Postby planecrazzzy » Sat Dec 18, 2010 12:30 pm

Now the piece is ready to be rolled... I layed out the area this is needed , and drew lines across the sheet...

this will help keep things "Square"... in a curved sorta way....
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After , the pattern was used to determine where to bend the extra material ( Using the full 48 inches )
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Then , time to slip the tank in place.... With it in position... I marked how "high" I wanted the upper extension to be....

Then , back to the brake to make the bend....
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. Gotta Fly...
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Attachments
Fuel Tank 004.jpg
Fuel Tank 005.jpg
Fuel Tank 006.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Re: Fuel Tank

Postby planecrazzzy » Sat Dec 18, 2010 12:38 pm

This three in one tool is paying for it's self...

Actually , it could be sold after the project , and re coupe most of the money.... I'll keep mine

It's the 40"..... anything less , wouldn't do the job.... anything more , cost too damn much...
Attachments
Fuel Tank 009.jpg
The baffle fits good... It will be welded in the center of the tank...
Fuel Tank 007.jpg
The tank "IS" supposed to be two inches higher on one side... it will be finished off with more material later
Fuel Tank 008.jpg
It fits good , and has good clearance on the sides...
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Fuel Tank

Postby planecrazzzy » Tue Dec 21, 2010 7:18 pm

Hey Guys ,
If I did it again.... I'd do it different... I tacked the center baffle in place... I should have had the end caps in place first...

I didn't realize how much this thin Aluminum would warp... Aluminum is not my strong suite ....Especially thin stuff...

I made my end caps... I put three bead lines in them... to stop "oil Canning"...

and I used the beader to roll the edge... this saved making a plywood plug and beating the edges over....

I still had to tap the edges... but not much ...

When I went to put the end caps on... I had to pull on the main tank pretty good...

When I started doing the other side... it was "off" too much.... I had to cut a tack loose from the center baffle...

But I ended up with both caps "on" and they are tack welded...
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Gotta Fly...
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Attachments
Fuel Tank 010.jpg
Fuel Tank 011.jpg
Fuel Tank 012.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Re: Fuel Tank

Postby planecrazzzy » Tue Dec 21, 2010 7:22 pm

mo pix
Attachments
Fuel Tank 013.jpg
Fuel Tank 014.jpg
Fuel Tank 015.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Re: Fuel Tank

Postby planecrazzzy » Tue Dec 21, 2010 7:29 pm

Hey Guys ,
At this point , I tapped the caps with a rubber hammer , bowing them "out" slightly...

After I have a root pass around everything.... I'll add a cover pass....

But for now , I want to get the tank pieces all together...

I have some trimming to do , and pieces to make...

The parts I ordered for the tank will be here in a couple of days...
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Gotta Fly...
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Attachments
Fuel Tank 016.jpg
Fuel Tank 017.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Fuel Tank

Postby planecrazzzy » Thu Dec 23, 2010 7:51 am

Using the Nibbler with a vacuum hose taped on it .... it grabs the little half moons before they go flying...

I put a drop of oil about every 6 inches... and clamp the straight edge tight.
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This is the last piece to seal the tank...
Gotta Fly...
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Attachments
Fuel Tank 018.jpg
Fuel Tank 019.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Fuel Tank

Postby planecrazzzy » Thu Dec 23, 2010 7:55 am

Using the "Beader" , I put a step in the edge that will tuck under the top flat piece of aluminum on the tank...

This will support it better...
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,
Gotta Fly...
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Attachments
Fuel Tank 020.jpg
Fuel Tank 021.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
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Location: Minnesota

Re: Fuel Tank

Postby planecrazzzy » Thu Dec 23, 2010 8:14 am

Hey Guys,
I got the last piece drilled and deburred...

I'll wait on welding for now... I'll be getting my parts later today... I need to make sure my "sender" arm has room...

Also , I need to cut a hole , weld a plate and Flange on the bottom for the fuel line , So there's some clean up that's needed...

I replaced the cleco's that were close to the firewall with #6 screws , These will hold it temporary while I check "fit-up"

and lay-out of the tank straps.... Looks like about 4 inches from the end... Can't go much more than that or it'll bow the cross tube...
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Gotta Fly...
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Attachments
Fuel Tank 022.jpg
Fuel Tank 023.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Location: Minnesota

Re: Fuel Tank

Postby planecrazzzy » Thu Dec 23, 2010 10:45 pm

I got my parts from Aircraft Spruce today...

First I worked on mounting the Sender...

I picked a spot that I thought was best... Passenger side , and in an area that is furthest from welding...

Maybe the surface will stay flat...

Something I didn't realize... the five bolt pattern is NOT even.... Something isn't symmetrical...

I didn't find out until I went to put the gasket in place , to trace the center hole...

Some how , I lucked out.... it was like I wanted it...

I have full stroke , empty to full
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Gotta Fly...
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Attachments
Fuel Tank 025.jpg
Fuel Tank 026.jpg
Fuel Tank 027.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Fuel Tank

Postby planecrazzzy » Thu Dec 23, 2010 10:46 pm

I also got the plate and flange welded today...
Gotta Fly...
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.
Attachments
Fuel Tank 028.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Location: Minnesota

Re: Fuel Tank

Postby planecrazzzy » Fri Dec 31, 2010 9:51 pm

Hey Guys,
I finished welding the Tank.... Although , I still need to weld the "Filler" and vent tube on it...

But First... I need to test it... I put the sender in place ( to seal the hole )

and I put a ball valve at the bottom... I added air until I heard a "pop"

That didn't take long... I didn't over pressure the tank...

I used Palmolive soap ( Diluted ) to spray it down and look for leaks...

I found two... one was on an edge... I should have seen it...

The other was a tiny spot at the outlet...

I got them both re welded... and tested it again... No Leaks....

I left the air in the tank overnight... it held...

I'll be making the straps to hold the tank in place...

After I get the filler tube welded and the flush cap in the windshield... I'll fill it with water...
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Also , Since the tank is so big.... I took back a little by Denting in the "Toe Area" with a Ball peen hammer...
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Now I have plenty of room... Also , This helps "Funnel" the last fuel towards the outlet...
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Gotta Fly...
Mike & "Jaz" in MN
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Attachments
Fuel Tank 029.jpg
Fuel Tank 030.jpg
Fuel Tank 031.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: (21) Fuel Tank ( Mike)

Postby planecrazzzy » Tue Jan 04, 2011 10:51 am

Hey Guys,
Ok... Lets mount this thing...

I changed the way the straps are normally done.... and it doesn't look like I need straps going over the top of the tank...

The "step" I formed in the aluminum tank, keeps it from rising when tightened...

I used Stainless steel straps... one inch wide... ( it fits the Rubber channel I bought from ACS )

and I made the front straps so they will "unbolt"...

Another "mod"... the tube that the threaded rod goes through was welded on a plate first..

This will spread out the load of my "Heavier" than stock Tank....

Another note... I was going to put the straps towards the inside a little more...

But denting in the bottom of the tank in the toe area , made me decide to keep the straps towards the outside....

otherwise they interfere with the extra toe room....
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Here's some pix...
Gotta Fly...
Mike & "Jaz" in MN
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Attachments
Fuel Tank 032.jpg
Fuel Tank 033.jpg
Fuel Tank 034.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: (21) Fuel Tank ( Mike)

Postby planecrazzzy » Tue Jan 04, 2011 11:04 am

mo pix
Attachments
Fuel Tank 037.jpg
Fuel Tank 038.jpg
Fuel Tank 039.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

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