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Fuel Filler Frustration

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dgardea(at)gmail.com

Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN

Posted: Thu Jan 03, 2008 3:53 pm Post subject: Fuel Filler Frustration

Hello all,



I have seen some posts on this topic a while back and hesitate to start a new thread, but wanted to see if anyone has developed any new techniques for leveling out their fuel filler neck on the tank. See the attached picture .. one side is about 3mm higher than the other. I know one lister was able to correct this by hammering down one side with a solid piece of maple. I tried this carefully, but the threaded neck just seems to rebound to it's original out of level position. Any experience in solving this is appreciated before I give Zenith a call tomorrow. 



Thanks,



Dave Gardea

Just ordered fuselage kit and related components today..

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_________________
Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html

lwinger

Joined: 21 Jun 2006
Posts: 229
Location: Tustin, CA

Posted: Thu Jan 03, 2008 4:14 pm Post subject: Fuel Filler Frustration

Dave, 

  

 I just finished dealing with the same problem, and also tried to tweak the neck.  Not much luck for me either!  My fix was to use small pieces of cork strip to build up the area between the tank and the skin on the side of the gap (right side on your photo).  When I tightened the filler neck, that side was held higher while the remaining area was compressing normally.  The gap disappeared, for all practical purposes. 

  

 Good luck!

  

 Larry Winger

 Tustin, CA

 Scratchbuilding 601XL/Corvair

 Wings done!  Starting the fuselage. 

  [quote][b]

_________________
Larry Winger
Tustin, CA
Plans building 601XL/650 with Corvair
Installing fuel system
www.mykitlog.com/lwinger

Michael Valentine

Joined: 09 Jan 2006
Posts: 108

Posted: Thu Jan 03, 2008 5:53 pm Post subject: Fuel Filler Frustration

Hammer harder!  (Not that I really liked that method.)  I used the hammer technique and then added quite a bit of cork to try to make my filler flush.



Michael in NH



On Jan 3, 2008 6:53 PM, dgardea(at)gmail.com < dgardea(at)gmail.com (dgardea(at)gmail.com)> wrote:

[quote]--> Zenith-List message posted by: "dgardea(at)gmail.com" < dgardea(at)gmail.com (dgardea(at)gmail.com)>



Hello all,



I have seen some posts on this topic a while back and hesitate to start a new thread, but wanted to see if anyone has developed any new techniques for leveling out their fuel filler neck on the tank. See the attached picture .. one side is about 3mm higher than the other. I know one lister was able to correct this by hammering down one side with a solid piece of maple. I tried this carefully, but the threaded neck just seems to rebound to it's original out of level position. Any experience in solving this is appreciated before I give Zenith a call tomorrow. 



Thanks,



Dave Gardea

Just ordered fuselage kit and related components today..



--------

Dave Gardea

601XL - Corvair

working on wings

 http://home.comcast.net/~davegardea/





Read this topic online here:



http://forums.matronics.com/viewtopic.php?p=155818#155818  [quote][b]

macleod(at)eagle.ca
Guest

Posted: Thu Jan 03, 2008 6:07 pm Post subject: Fuel Filler Frustration

 	  Quote: 	
		  .. one side is about 3mm higher than the other.


	


Dave:  I had the same problem, only mine was much worse on one side.



After careful consideration I ignored all advice and filed the threads off

the filler necks until they slipped easily into the tank in a perfectly

level position (they had a beautiful machined thread), bought some goop

guaranteeed to seal gasoline systems and gooped them on.



They now look perfect.



My solution may not be for all but it worked.



Mike

601XL

waiting patiently for Rotax FWFwd

Afterfxllc(at)aol.com
Guest

Posted: Thu Jan 03, 2008 6:52 pm Post subject: Fuel Filler Frustration

That is exactly what you have to do...  When you build up the cork it  forces the tank metal to conform and it lay flat as a pancake just be  careful because the more you put the filler cap in and out it seems to get  harder and harder to take out. The point is you will have to play with it  to get it just right.

  

  

  	  Quote: 	
		     Dave, 

    

   I just finished dealing with the same problem, and also tried to tweak    the neck.  Not much luck for me either!  My fix was to use small    pieces of cork strip to build up the area between the tank and the skin on the    side of the gap (right side on your photo).  When I tightened the filler    neck, that side was held higher while the remaining area was compressing    normally.  The gap disappeared, for all practical    purposes.

	


 

  



Start the year off right.  Easy ways to stay in shape in the new year. 

  [quote][b]

ding(at)tbscc.com
Guest

Posted: Thu Jan 03, 2008 7:35 pm Post subject: Fuel Filler Frustration

Dave,

            I used a hardwood block set flat on the filler neck top, and 

whacked it as needed with a heavy mallet. I had to hit it hard on the high 

side, but in a few minutes, checking progress with a straightedge, problem 

gone. I had th tank supported on carpet and foam.  The other issue with the 

earlier tanks that have filler neck welded on top of the tank, is getting 

the filler to sit low enough that the lid will screw in far enough to meet 

the skin. The crude hammer method helps that as well. Just don't "test fit" 

the threaded section  without applying anti sieze to the threads first, they 

will lock up if you aren't lucky.

                                                                             

                                                                Lynn 

Corry, PA



 	  Quote: 	
		   I have seen some posts on this topic a while back and hesitate to start a 

 new thread, but wanted to see if anyone has developed any new techniques 

 for leveling out their fuel filler neck on the tank. See the attached 

 picture .. one side is about 3mm higher than the other. I know one lister 

 was able to correct this by hammering down one side with a solid piece of 

 maple. I tried this carefully, but the threaded neck just seems to rebound 

 to it's original out of level position. Any experience in solving this is 

 appreciated before I give Zenith a call tomorrow.



 Thanks,



 Dave Gardea

 Just ordered fuselage kit and related components today..



 --------

 Dave Gardea

 601XL - Corvair

 working on wings

 http://home.comcast.net/~davegardea/





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=155818#155818





 Attachments:



 http://forums.matronics.com//files/img_0066_136.jpg

Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Thu Jan 03, 2008 8:47 pm Post subject: Re: Fuel Filler Frustration

I'm the guy who hit it with the maple block.  I placed more pictures on picasaweb to show how I did it.



http://picasaweb.google.com/ron.lendon/FuelFiller



Aluminum has a lot of springback, it takes quite a lot of movement to get it to take a set.  I whacked it a few times before it was where it needed to be and it didn't deform the bottom of the skin.  The entire wing is supported on 6" Styrofoam blocks when this operation was performed.  I just Clecoed everything in place and just hit it where the high spot was.

_________________
Ron Lendon
WW Corvair with Roy's Garage 5th bearing
CH 601 XLB
N601LT - Flying
http://www.mykitlog.com/rlendon
Corvair Engine Prints:
https://sites.google.com/site/corvairenginedata/

dgardea(at)gmail.com

Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN

Posted: Fri Jan 04, 2008 4:38 am Post subject: Re: Fuel Filler Frustration

Guys,



Thanks for all your prompt and helpful replies. Ron, thanks for posting the very detailed sequence of pictures. Happy building and hope everyone can stay warm in those garages. Been in the single digits here in Indiana.



Regards,



Dave

_________________
Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html

4RCSIMMONS(at)comcast.net
Guest

Posted: Fri Jan 04, 2008 6:05 am Post subject: Fuel Filler Frustration

Dave,



If I remember correctly, I reinforced my circumference of the fuel filler neck area with the cork used on the exterior of the tank. This allowed mt to put a slight clamp load on the assembly and it all seemed to fit together well.



Good Luck.



Rich Simmons

601 XL Fuselage upper  - Front

PatrickW

Joined: 27 Oct 2006
Posts: 380
Location: Fort Worth, Texas

Posted: Fri Jan 04, 2008 6:39 am Post subject: Re: Fuel Filler Frustration

I had already closed my wings when I found out how poorly the fit was in this area.



Here's how I solved it:  http://picasaweb.google.com/Patrick.Hoyt/FuelTankFillerFix



I've noticed Zodiacs at fly-ins where the builder just left it alone and lived with the big dimple, but I didn't want that on my airplane.  



It's not hard to fix, and can easily be done "after the fact".



One other solution that I've seen on Zodiacs is where the builder fabricates about a 6 inch circle of sheet metal, with a hole in it through which the treaded bushing is inserted.  Think of a "doughnut" shape that covers the whole area.  



Patrick

XL/Corvair

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