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sight glass fuel indicator?
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WurlyBird



Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

PostPosted: Fri Dec 05, 2008 4:23 pm    Post subject: sight glass fuel indicator? Reply with quote

I am happy to announce that I have finally purchased a Kitfox III that will be waiting for me when I get home from Afghanistan. My buddy that did the test flight and inspection for me indicated that there were no fuel gauges on the wing tanks, 6 gal variety. John McB has told me to check if there were holes that were covered because he thinks there might have been some on that style fuel tank but he had never seen an install done after assembly. For right now I am guessing worst case and assuming there is not. Has anyone ever installed or seen/heard of an installation of a sight glass or sight tube type fuel gauge after the plane was assembled? Right now I am thinking that it should not be too hard besides having to work partially through the fuel cap opening and ensuring no debris remains in the tank. Am I completely wrong? Is there a good kit or specific sealant for something like this? Any information will be a great help. Thanks

James


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Kitfox 3 / 582 / 70" IVO 2 blade GA
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Paul A. Franz, P.E.



Joined: 02 Dec 2008
Posts: 280
Location: Bellevue WA

PostPosted: Fri Dec 05, 2008 5:57 pm    Post subject: sight glass fuel indicator? Reply with quote

On Fri, December 5, 2008 4:23 pm, WurlyBird wrote:
Quote:


My buddy that did the test flight and
inspection for me indicated that there were no fuel gauges on the wing tanks...

You might not need to go to the trouble of installing a sight glass on the wing tanks.
The header tank may be large enough for a comfortable reserve. You might be able to
see the fuel in a clear line coming from a wing tank and if the header tank holds
enough for your reserve requirement then that could be sufficient. You could also
install a low fuel alarm in the header tank. Some of the header tanks hold half an
hour or more reserve.

You might also talk to the previous owner and find out what his procedure was.

--
Paul A. Franz
Registration/Aircraft - N14UW/Merlin GT
Engine/Prop - Rotax 914/NSI CAP
Bellevue WA
425.241.1618 Cell


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Tom Jones



Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA

PostPosted: Fri Dec 05, 2008 8:11 pm    Post subject: Re: sight glass fuel indicator? Reply with quote

Quote:
Has anyone ever installed or seen/heard of an installation of a sight glass or sight tube type fuel gauge after the plane was assembled? Right now I am thinking that it should not be too hard besides having to work partially through the fuel cap opening and ensuring no debris remains in the tank. Am I completely wrong? Is there a good kit or specific sealant for something like this? Any information will be a great help. Thanks

James


James, you are correct. The worst case is you will have to drill and tap the two holes to install the site gage. The main Issue will be getting all the debris out of the tank. A trick is to grease the drill bit so the debris stick to it. An adapter on a shop vac would probably work but you may get the "Big Bang" from fuel fumes.

Quarter inch polyurathane fuel line and brass fittings (pipe thread to hose barb). Seal with a fuel proof non harding sealer.


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Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA
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Guy Buchanan



Joined: 16 Jul 2006
Posts: 1204
Location: Ramona, CA

PostPosted: Sat Dec 06, 2008 12:01 am    Post subject: sight glass fuel indicator? Reply with quote

At 04:23 PM 12/5/2008, you wrote:
Quote:
Right now I am thinking that it should not be too hard besides
having to work partially through the fuel cap opening and ensuring
no debris remains in the tank. Am I completely wrong?

James,
Congratulations and welcome! I don't think you'll have to
get out your ship-in-a-bottle tools. I installed tank vents inboard
after-the-fact by first getting access through the butt rib. I then
used my Dremel to sand a 1 1/2" diameter area down to the glass. I
left it rough because I then epoxied a 1 1/4" diameter 1/4" thick
G-10 plate to the tank. I could then drill and tap this plate for a
1/8 NPT to barb fitting to which I attached my valve. You could do
the same top and bottom for the level ports. (Of course you have to
flush the tanks well after doing so.) You won't get your ports right
up against the top and bottom of the tank. To do that would require
you to lay-up your own reinforcements so they go around the corner; a
much harder job.
Guy Buchanan
San Diego, CA
K-IV 1200 / 582-C / Warp / 100% done, thanks mostly to Bob Ducar.


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Lynn Matteson



Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

PostPosted: Sat Dec 06, 2008 4:36 am    Post subject: sight glass fuel indicator? Reply with quote

A bigger "worse case" in my mind is whether you will be drilling into
an area that has not been sufficiently thickened with fiberglas so as
to provide a boss into which more than just a couple of threads can
be tapped. If those tanks weren't designed...at that particular
area...for the installation of the threaded nipples, you won't have
any holding power. Of course, you can always build up the area with
fiberglas and resin first.

Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 593hrs
Sensenich 62x46
flying again after rebuild, and new Electroair direct-fire ignition
system;
also building a new pair of snow skis


On Dec 5, 2008, at 11:11 PM, Tom Jones wrote:

Quote:

> Has anyone ever installed or seen/heard of an installation of a
> sight glass or sight tube type fuel gauge after the plane was
> assembled? Right now I am thinking that it should not be too hard
> besides having to work partially through the fuel cap opening and
> ensuring no debris remains in the tank. Am I completely wrong? Is
> there a good kit or specific sealant for something like this? Any
> information will be a great help. Thanks
>
> James
James, you are correct. The worst case is you will have to drill
and tap the two holes to install the site gage. The main Issue
will be getting all the debris out of the tank. A trick is to
grease the drill bit so the debris stick to it. An adapter on a
shop vac would probably work but you may get the "Big Bang" from
fuel fumes.

Quarter inch polyurathane fuel line and brass fittings (pipe thread
to hose barb). Seal with a fuel proof non harding sealer.

--------
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA


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Kitfox IV-Jabiru 2200
N369LM
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Beemer



Joined: 26 Aug 2006
Posts: 87
Location: Middle Georgia

PostPosted: Sat Dec 06, 2008 5:35 am    Post subject: sight glass fuel indicator? Reply with quote

James,
There's no need to thread anything into the fiberglass. Drill holes at the
very top and bottom, and epoxy in short aluminum tubes to which you will
attach the clear tubing. Threads suck in this application most of the time,
and they leak, get cross threaded easily, and will strip out about the third
time you pull the tubing off of them.

You can also get some float fuel senders and install them in the root
surface of the tank. Then, there are about a 100 fuel level gauges available
to hook them up to. My EFIS takes the fuel level and readings from the fuel
flow sender, and gives me a rough calculation of the airplanes range and
time to empty at that speed. It's only an estimate, but it's useful for
planning. You can get a similar instrument for about $250. Or a couple of
fuel level gauges for $50.

Whatever you do, be aware that gasoline is about the hardest stuff
imaginable to seal against, as 95% of the sealants available are not
compatible. ProSeal is very compatible, but is prohibitively expensive. JB
Weld is good, as is the "clay" type tank repair epoxy available at auto
parts stores. Most all RTV type sealants are not usable for gasoline.

My option would be to drill close tolerance holes, press in 1/4 inch tubes
with JB Weld, and thoroughly flush the tanks with 1000 gallons of water.

Bradley

[quote] --


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Lynn Matteson



Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

PostPosted: Sat Dec 06, 2008 8:23 am    Post subject: sight glass fuel indicator? Reply with quote

Regarding thread stripping....if you drill and thread to 1/4" NPT,
and install 1/4 NPT-to-1/8 NPT reducing bushings, you'll only have to
install into the tank one time. I'd prefer this method to tubing
which is epoxied in place...too little mechanical grip with this
method, but that's just me.

Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 593hrs
Sensenich 62x46
flying again after rebuild, and new Electroair direct-fire ignition
system;
also building a new pair of snow skis


On Dec 6, 2008, at 8:26 AM, Bradley Webb wrote:

Quote:


James,
There's no need to thread anything into the fiberglass. Drill holes
at the
very top and bottom, and epoxy in short aluminum tubes to which you
will
attach the clear tubing. Threads suck in this application most of
the time,
and they leak, get cross threaded easily, and will strip out about
the third
time you pull the tubing off of them.


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Kitfox IV-Jabiru 2200
N369LM
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PostPosted: Sat Dec 06, 2008 8:51 am    Post subject: sight glass fuel indicator? Reply with quote

WurlyBird wrote:
Quote:

<james.t.trizzino(at)us.army.mil>

I am happy to announce that I have finally purchased a Kitfox III
that will be waiting for me when I get home from Afghanistan. My
buddy that did the test flight and inspection for me indicated that
there were no fuel gauges on the wing tanks, 6 gal variety. John McB
has told me to check if there were holes that were covered because he
thinks there might have been some on that style fuel tank but he had
never seen an install done after assembly. For right now I am
guessing worst case and assuming there is not. Has anyone ever
installed or seen/heard of an installation of a sight glass or sight
tube type fuel gauge after the plane was assembled? Right now I am
thinking that it should not be too hard besides having to work
partially through the fuel cap opening and ensuring no debris remains
in the tank. Am I completely wrong? Is there a good kit or specific
sealant for something like this? Any information will be a great
help. Thanks

James

James,

When I bought my Speedster kit, I also got the mechanical fuel gauge
kit. It installs entirely from the outside of the tank. You might check
with John McB to see if they are still available. If not, you can get
the gauge from Aircraft Spruce and I have the instructions.

Dennis
--
Dennis Golden
Golden Consulting Services, Inc.


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JetPilot



Joined: 10 Jan 2006
Posts: 1246

PostPosted: Sat Dec 06, 2008 3:07 pm    Post subject: Re: sight glass fuel indicator? Reply with quote

I would not drill into the tank, it seems you are asking for trouble. I would go with the fuel indicator in the reserve tank.. If you had to have a fuel indicator, then I would get an electronic one so that you wont have problems with leaks, etc...

Seems like a lot of trouble and problems just to have sight tubes on the tank. Leaks from holes below the gas line can be a problem.. You will never be able to drill into a plastic tank and keep all the debris out, I know that from experience. Even after having the tank out, sloshing, rinsing, sloshing with gasoline several times, I still get bits of plastic in the gascolator in my other airplane. Think real hard before you start drilling !!!

Mike


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Beemer



Joined: 26 Aug 2006
Posts: 87
Location: Middle Georgia

PostPosted: Sat Dec 06, 2008 7:04 pm    Post subject: sight glass fuel indicator? Reply with quote

Lynn,

The idea of using the threaded reducer is a very good one. One could epoxy
that in place so it's would stay permanently. The only small issue I could
see is that the port will not be at the very bottom of the tank.

Bradley

[quote] --


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PostPosted: Sat Dec 06, 2008 11:19 pm    Post subject: sight glass fuel indicator? Reply with quote

For what it's worth, the reducer is a long time practice with Kitfox for the
finger strainers which are, or should be, removed periodically for
inspection. Thinking of the finger strainers, I don't think with these in
place and the usual down line fuel filters, I would hesitate drilling for
sight gauges. I think there are methods to remove most drill debris and
methods to reduce it.

I think, what I would do is make a boss out of fiberglass, drill and tap the
boss, then glue it in the desired place with Hysol. Then take a #30 or so
drill and drill down the center of the threaded boss. This way you don't
have to put a drilled plug in the tubing to dampen surges in the sight
gauge. The sight gauges are standard on the Model IV and up so they have
tons of long term use. I think the leakage issues of time past have been
resolved with different fittings and lots of home brew methods for nice
looking and quite accurate gauges - mine - I could estimate within a gallon
or so. Personally, I would much rather look at my fuel than a needle if
fuel was a critical issue at any time.

I talked to a guy recently that mistook a vertical needle as half full, when
it actually was on flat out empty. Then we can all recall stories of folks
that suffered engine outs with lots of fuel still showing on the gauge. Not
much chance of error with a puddle of gas in a plastic tube.

If you haven't worked much with fiberglass, cover the desired areas top and
bottom with clear packing tape and then lay on a couple of layers of
fiberglass. When it cures, pop the glass off and using that as a bases, lay
up enough additional layers for sufficient threads to hold the fitting.
Drill and tap and trim to a reasonable shape and size and after roughing
both mating surfaces glue it in place with Hysol or some other structural
adhesive. Drill the tiny hole and put the fittings and tubing together.
With this method, the only clearance issues would be fitting issues and it
could be placed pretty close to the top and bottom of the tank. Any debris
from the drilling would be minimal and easily trapped in the fiters.

Lowell Fitt
Cameron Park, CA
Model IV-1200 R-912 UL
Currently focusing on the Left Wing, Rudder Gap Seal Cuffs and Landing Gear
Fairing

---


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WurlyBird



Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

PostPosted: Sat Dec 06, 2008 11:24 pm    Post subject: Re: sight glass fuel indicator? Reply with quote

JetPilot wrote:
I would go with the fuel indicator in the reserve tank.. If you had to have a fuel indicator...

Seems like a lot of trouble and problems just to have sight tubes on the tank.
Mike


I can appreciate that this is a task that has to be handled carefully for many reasons, my favorite of which to think about is the exploding vacuum. The guy I bought the plane from was simply calculating 4 gph burn and assuming full tanks at take off as his method. I know that the point of sport flying is having fun and relaxing but my nature and training prohibit me from relaxing while waiting for the fuel to get low in order for me to have any idea how much I actually have. Not to mention with only a 1050 gross I may have to calculate how much fuel I can take if I have a heavy load. I will feel much better being able to look at the tubes and see how much fuel is in each tank. So to me it is worth the trouble, and of course worth the trouble to do it right the first time.

Thanks for all the suggestions, I now feel that it is definitely more simple then some of the worse case scenarios I had in my head. I will look into it more once I get home. By the way, is Proseal one of the best compounds for gluing in a fuel covered environment?


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Kitfox 3 / 582 / 70" IVO 2 blade GA
50 hrs on the 582 swapping for HKS 700E and Avid Cowl.
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Lynn Matteson



Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

PostPosted: Sun Dec 07, 2008 6:18 am    Post subject: sight glass fuel indicator? Reply with quote

I'm not sure if epoxy would stick to the brass, would it? Maybe scuff
it up real good, or better yet, chuck it up in a lathe and knurl the
outside of the threaded area, then epoxy in place. That would
certainly make enough of a "bitable surface" for epoxy adherence.

As far as getting it right down to the bottom of the tank, remember
this is only for a sight gauge, so not being able to visibly read the
very last drop of fuel would be a good thing...you'd be landing for a
fill-up before you got into an emergency situation (said the guy who
flies with one wing low so the other can feed his header tank, and
thereby make it to the next stop) : )

Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 593hrs
Sensenich 62x46
flying again after rebuild, and new Electroair direct-fire ignition
system;
also building a new pair of snow skis
do not archive

On Dec 6, 2008, at 10:03 PM, Bradley Webb wrote:

Quote:


Lynn,

The idea of using the threaded reducer is a very good one. One
could epoxy
that in place so it's would stay permanently. The only small issue
I could
see is that the port will not be at the very bottom of the tank.

Bradley


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Kitfox IV-Jabiru 2200
N369LM
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Lynn Matteson



Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

PostPosted: Sun Dec 07, 2008 6:26 am    Post subject: sight glass fuel indicator? Reply with quote

I haven't thought about gluing with Proseal, but have seen it used to
*seal* a fuel tank....one of the guys at our EAA chapter is building
a plane and had so many leaking issues with his tank that when he
finally got it to seal using (a LOT of) Proseal, he said he was gonna
call the factory and tell them that they could now lay off the second
shift. : )

Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 593hrs
Sensenich 62x46
flying again after rebuild, and new Electroair direct-fire ignition
system;
also building a new pair of snow skis
do not archive

On Dec 7, 2008, at 2:24 AM, WurlyBird wrote:

Quote:

<james.t.trizzino(at)us.army.mil>
JetPilot wrote:
> I would go with the fuel indicator in the reserve tank.. If you
> had to have a fuel indicator...
>
> Seems like a lot of trouble and problems just to have sight tubes
> on the tank.
> Mike
I can appreciate that this is a task that has to be handled
carefully for many reasons, my favorite of which to think about is
the exploding vacuum. The guy I bought the plane from was simply
calculating 4 gph burn and assuming full tanks at take off as his
method. I know that the point of sport flying is having fun and
relaxing but my nature and training prohibit me from relaxing while
waiting for the fuel to get low in order for me to have any idea
how much I actually have. Not to mention with only a 1050 gross I
may have to calculate how much fuel I can take if I have a heavy
load. I will feel much better being able to look at the tubes and
see how much fuel is in each tank. So to me it is worth the
trouble, and of course worth the trouble to do it right the first
time.

Thanks for all the suggestions, I now feel that it is definitely
more simple then some of the worse case scenarios I had in my
head. I will look into it more once I get home. By the way, is
Proseal one of the best compounds for gluing in a fuel covered
environment?

--------
Prospective Kitfox buyer
Here for information on airframes and engines


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Beemer



Joined: 26 Aug 2006
Posts: 87
Location: Middle Georgia

PostPosted: Mon Dec 08, 2008 4:21 am    Post subject: sight glass fuel indicator? Reply with quote

The AN series aluminum reducers would work better than brass, I'd think.
Taps are tapered, so you could size the threads smaller than normal, and get
a good "bite", such that the adhesive would only serve to seal it and hold
it in place.

BTW, I slip to feed the header in the exact same way. But my fuel system is
designed to detect header feed and level, not so much fuel level in the
tanks.

Because I run a fuel injected engine which requires pressure, I have a flow
sender that tells me flow into the header, and a level switch in the header
tank to detect anything less than full. With this setup, no fuel flow
indication means my header is not getting filled, and I wait for the light
to come on, which indicates about 45 minutes of run time remaining at that
point.

It works nicely, in that I can do whatever is required to keep feeding the
header tank (slip, etc.) and when the light goes on, I have VFR fuel
reserve, and need to land. I know that at 21 in/hg, I flow about 2.2gph, so
less flow indicates no header feeding, such as a blockage. More flow
indicates the header has gotten low, and is refilling itself. Either way,
the fuel pump is sending fuel to the engine.

Actually, my fuel tank level senders are superfluous, and only serve to
provide an estimate of fuel level in flight. I use them more on preflight to
determine whether refueling is necessary. On my new Model three, I'm going
to do both senders and sight gauges, just for redundancy, and neither is
hard nor expensive to do.

Bradley

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PostPosted: Mon Dec 08, 2008 8:28 am    Post subject: sight glass fuel indicator? Reply with quote

For what it's worth, over the weekend I rethought my suggested method for
retrofitting a sight gauge in an already installed tank and thought of one
additional step. After the bosses are fabricated and tapped, I would
postition them in place, mark the position of the tapped hole, drill through
the tank - small hole -and Hysol a short length of aluminum tube through
the hole. The tube would protect the wall of the tank from constant contact
with fuel. Then I would Hysol the fabricted tapped boss to the side of the
tank.

Lowell

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PostPosted: Mon Dec 08, 2008 9:15 am    Post subject: sight glass fuel indicator? Reply with quote

Not to offend any of the possible solutions offered, but If she were
mine I would just add a small fuel flow gage to the panel. You can put
the pick up in the fuel supply line. Several are offered and have many
advantages over just looking up to see what is left. Not that that is a
bad thing, far from it. But at this point in the finished state of the
aircraft it just makes more sense to me.

If you do decide to go with the sight tubes let me know and I will look
to see what I have laying around. Seems I was going to replace something
and had to buy the entire kit. If you do drill the fiberglass for
fittings might I suggest you do a bit of glass layer build up first. You
could also put in some nice permanent bushings to screw your tube
fittings in to.


Rick


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PMorel



Joined: 09 Jul 2007
Posts: 62
Location: Locust Grove, GA USA

PostPosted: Mon Dec 08, 2008 12:39 pm    Post subject: sight glass fuel indicator? Reply with quote

Here's about the cheapest Fuel Flow system I found. I got it a little
cheaper at Oshkosh this past summer and it's going in my Speedster.
http://www.fdatasystems.com/

Paul Morel
Model IV Speedster
Locust Grove, GA

---


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Paul Morel
912 Speedster
Locust Grove, GA

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Lynn Matteson



Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

PostPosted: Mon Dec 08, 2008 2:16 pm    Post subject: sight glass fuel indicator? Reply with quote

My two wing tanks feed the header tank, which, when full, fills up
the low fuel indicator tank and then back up to the right wing tank.
As long as I've got no yellow light on, I'm good for at least 15
minutes flight. But when I know I'm low on fuel, I'll glance at the
clear line between the low fuel indicator tank and the right wing,
and if it starts to show air instead of fuel, then I've got a heads-
up that the yellow (low fuel) light will soon glow, indicating that
I've got 15 minutes to find fuel or go into the low-wing method of
transferring fuel to the header tank. It's a lot less scary than it
sounds!

Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 593hrs
Sensenich 62x46
flying again after rebuild, and new Electroair direct-fire ignition
system;
also building a new pair of snow skis
do not archive

On Dec 8, 2008, at 7:21 AM, Bradley Webb wrote:

Quote:


BTW, I slip to feed the header in the exact same way. But my fuel
system is
designed to detect header feed and level, not so much fuel level in
the
tanks.

Bradley


Quote:
> As far as getting it right down to the bottom of the tank, remember
> this is only for a sight gauge, so not being able to visibly read the
> very last drop of fuel would be a good thing...you'd be landing for a
> fill-up before you got into an emergency situation (said the guy who
> flies with one wing low so the other can feed his header tank, and
> thereby make it to the next stop) : )
>
> Lynn


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Kitfox IV-Jabiru 2200
N369LM
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PostPosted: Mon Dec 08, 2008 3:23 pm    Post subject: sight glass fuel indicator? Reply with quote

Lynn C Please explain the "low wing method". Thanks.
 
Pat reilly
Mod 3582 Rebuild
Rockford C IL

Quote:
From: lynnmatt(at)jps.net
Subject: Re: sight glass fuel indicator?
Date: Mon C 8 Dec 2008 17:15:28 -0500
To: kitfox-list(at)matronics.com

--> Kitfox-List message posted by: Lynn Matteson <lynnmatt(at)jps.net>

My two wing tanks feed the header tank C which C when full C fills up
the low fuel indicator tank and then back up to the right wing tank.
As long as I've got no yellow light on C I'm good for at least 15
minutes flight. But when I know I'm low on fuel C I'll glance at the
clear line between the low fuel indicator tank and the right wing C
and if it starts to show air instead of fuel C then I've got a heads-
up that the yellow (low fuel) light will soon glow C indicating that
I've got 15 minutes to find fuel or go into the low-wing method of
transferring fuel to the header tank. It's a lot less scary than it
sounds!

Lynn Matteson
Kitfox IV Speedster C taildragger
Jabiru 2200 C #2062 C 593hrs
Sensenich 62x46
flying again after rebuild C and new Electroair direct-fire ignition
system;
also building a new pair of snow skis
do not archive



On Dec 8 C 2008 C at 7:21 AM C Bradley Webb wrote:

> --> Kitfox-List message posted by: "Bradley Webb" <bmwebb(at)cox.net>
>
> BTW C I slip to feed the header in the exact same way. But my fuel
> system is
> designed to detect header feed and level C not so much fuel level in
> the
> tanks.
>
> Bradley


>> As far as getting it right down to the bottom of the tank C remember
>> this is only for a sight gauge C so not being able to visibly read the
>> very last drop of fuel would be a good thing..you'd be landing for a
>> fill-up before you got into an emergency situation (said the guy who
>> flies with one wing low so the other can feed his header tank C and
>> thereby make it to the next stop) : )
>>
&gt=====================

Quote:
_=======




[quote][b]


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