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galinhdz(at)gmail.com
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 Posted: Sun Nov 15, 2009 8:54 pm Post subject: Long Range Fuel Tanks |
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All;
After a LOT of work, we finally finished increasing the fuel capacity of my airplane. We (read mostly Rich) sealed up a bay just behind the existing fuel tank and created a cross flow from this bay to the existing one. Between the two bays we put a cross flow section and a fuel vent so the new fuel bay empties into the existing one via the cross flow eliminating having to complicate the existing fuel system. The cross flow section has an equivalent size of a 2" hole so plenty of fuel can cross over. It also has a fuel drain since water can possibly pool here. With this setup, I now have 46Gallons of useable fuel in each wing for a total of 92Gallons of fuel. I also added a metal tab which indicates approximately 30Gallons when the fuel reaches it. The max gross weight stays the same so I have a reduced payload with full fuel. It also slightly changed the fuel tank's center of gravity from 43 to 48". However even under all possible combinations of fuel loading, you can't get the CG out of limits.
It didn't go without a fight. The right wing went off without a hitch. We (once again read Rich) had a LOT of problems properly sealing the left wing tank. We had to open and seal the bay twice. Even then, it leaked and wound up having to dissasemble the wing twice before it was completely sealed.
With the 92Gallons of useable fuel, I now have 11.5hrs of endurance which translates to almost 1500NM range if burning 8GPH at max range speed of 130Kts. I am now limited by bladder capacity, not airplane fuel capacity. While flying around Central America I have arrived at airports that were supposed to have fuel but didn't. Now if this happens I can continue on to my next point instead of having to wait a few days for fuel to be delivered. I also took advantage of the fact the tanks were empty to verify the fuel meter indications and calibrate a "Universal FUELHAWK" fuel gauge specifically for my tanks as I filled them for the 1st time. I now have extended range as well as real good fuel management data.
I posted some pictures of the work on my webpage: http://puertoricoflyer.com/cgi-bin/photoalbum/view_album/191461
Galin
N819PR
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jerzy_krasinski(at)sbcglo
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| Posted: Mon Nov 16, 2009 4:51 am Post subject: Long Range Fuel Tanks |
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I have similar tanks in my plane.
However, II have hard time to understand the cross flow between the tanks.
The spar is in the way and drilling the spar does not look good.
Did you make the cross flow within the lower skin?
In my plane I installed extra pumps to transfer the fuel from the rear to the front.
The engine is fueled from the front tanks only.
I used the rear fuel tanks only once flying from Mt Pleasant, Michigan to Stillwater, Oklahoma. I put only 10 gal in each of the rear tanks for that flight, and of course full front tanks.
Jerzy
--- On Sun, 11/15/09, Galin Hernandez <galinhdz(at)gmail.com> wrote:
| Quote: |
From: Galin Hernandez <galinhdz(at)gmail.com>
Subject: Long Range Fuel Tanks
To: kis-list(at)matronics.com
Date: Sunday, November 15, 2009, 10:51 PM
All;
After a LOT of work, we finally finished increasing the fuel capacity of my airplane. We (read mostly Rich) sealed up a bay just behind the existing fuel tank and created a cross flow from this bay to the existing one. Between the two bays we put a cross flow section and a fuel vent so the new fuel bay empties into the existing one via the cross flow eliminating having to complicate the existing fuel system. The cross flow section has an equivalent size of a 2" hole so plenty of fuel can cross over. It also has a fuel drain since water can possibly pool here. With this setup, I now have 46Gallons of useable fuel in each wing for a total of 92Gallons of fuel. I also added a metal tab which indicates approximately 30Gallons when the fuel reaches it. The max gross weight stays the same so I have a reduced payload with full fuel. It also slightly changed the fuel tank's center of gravity from 43 to 48". However even under all possible combinations of fuel loading, you can't get the CG out of limits.
It didn't go without a fight. The right wing went off without a hitch. We (once again read Rich) had a LOT of problems properly sealing the left wing tank. We had to open and seal the bay twice. Even then, it leaked and wound up having to dissasemble the wing twice before it was completely sealed.
With the 92Gallons of useable fuel, I now have 11.5hrs of endurance which translates to almost 1500NM range if burning 8GPH at max range speed of 130Kts. I am now limited by bladder capacity, not airplane fuel capacity. While flying around Central America I have arrived at airports that were supposed to have fuel but didn't. Now if this happens I can continue on to my next point instead of having to wait a few days for fuel to be delivered. I also took advantage of the fact the tanks were empty to verify the fuel meter indications and calibrate a "Universal FUELHAWK" fuel gauge specifically for my tanks as I filled them for the 1st time. I now have extended range as well as real good fuel management data.
I posted some pictures of the work on my webpage: http://puertoricoflyer.com/cgi-bin/photoalbum/view_album/191461
Galin
N819PR
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ollow target=_blank>www.aeroelectric.com
/" rel=nofollow target=_blank>www.buildersbooks.com
ofollow target=_blank>www.homebuilthelp.com
llow target=_blank>http://www.matronics.com/contribution
=nofollow target=_blank>http://www.matronics.com/Navigator?KIS-List
et=_blank>http://forums.matronics.com
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galinhdz(at)gmail.com
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| Posted: Mon Nov 16, 2009 5:41 am Post subject: Long Range Fuel Tanks |
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Jerzy;
The cross flow goes under the spar between the tanks. Rich cut a hole in the bottom of each bay, then built the cross flow slightly underneath the wing. It has a slight bulge under the wing in a teardrop shape. Once closed up, it looks real good and makes a perfect place to put a fuel drain. This eliminated any transfer system or possible failure point.
I added two more pictures of the crossover to give a better idea.
Galin
N819PR
On Mon, Nov 16, 2009 at 6:50 AM, jerzy krasinski <jerzy_krasinski(at)sbcglobal.net (jerzy_krasinski(at)sbcglobal.net)> wrote:
[quote] I have similar tanks in my plane.
However, II have hard time to understand the cross flow between the tanks.
The spar is in the way and drilling the spar does not look good.
Did you make the cross flow within the lower skin?
In my plane I installed extra pumps to transfer the fuel from the rear to the front.
The engine is fueled from the front tanks only.
I used the rear fuel tanks only once flying from Mt Pleasant, Michigan to Stillwater, Oklahoma. I put only 10 gal in each of the rear tanks for that flight, and of course full front tanks.
Jerzy
--- On Sun, 11/15/09, Galin Hernandez <galinhdz(at)gmail.com (galinhdz(at)gmail.com)> wrote:
| Quote: |
From: Galin Hernandez <galinhdz(at)gmail.com (galinhdz(at)gmail.com)>
Subject: KIS-List: Long Range Fuel Tanks
To: kis-list(at)matronics.com (kis-list(at)matronics.com)
Date: Sunday, November 15, 2009, 10:51 PM
All;
After a LOT of work, we finally finished increasing the fuel capacity of my airplane. We (read mostly Rich) sealed up a bay just behind the existing fuel tank and created a cross flow from this bay to the existing one. Between the two bays we put a cross flow section and a fuel vent so the new fuel bay empties into the existing one via the cross flow eliminating having to complicate the existing fuel system. The cross flow section has an equivalent size of a 2" hole so plenty of fuel can cross over. It also has a fuel drain since water can possibly pool here. With this setup, I now have 46Gallons of useable fuel in each wing for a total of 92Gallons of fuel. I also added a metal tab which indicates approximately 30Gallons when the fuel reaches it. The max gross weight stays the same so I have a reduced payload with full fuel. It also slightly changed the fuel tank's center of gravity from 43 to 48". However even under all possible combinations of fuel loading, you can't get the CG out of limits.
It didn't go without a fight. The right wing went off without a hitch. We (once again read Rich) had a LOT of problems properly sealing the left wing tank. We had to open and seal the bay twice. Even then, it leaked and wound up having to dissasemble the wing twice before it was completely sealed.
With the 92Gallons of useable fuel, I now have 11.5hrs of endurance which translates to almost 1500NM range if burning 8GPH at max range speed of 130Kts. I am now limited by bladder capacity, not airplane fuel capacity. While flying around Central America I have arrived at airports that were supposed to have fuel but didn't. Now if this happens I can continue on to my next point instead of having to wait a few days for fuel to be delivered. I also took advantage of the fact the tanks were empty to verify the fuel meter indications and calibrate a "Universal FUELHAWK" fuel gauge specifically for my tanks as I filled them for the 1st time. I now have extended range as well as real good fuel management data.
I posted some pictures of the work on my webpage: http://puertoricoflyer.com/cgi-bin/photoalbum/view_album/191461
Galin
N819PR
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"_blank">www.aeroelectric.com
.com/" target="_blank">www.buildersbooks.com
="_blank">www.homebuilthelp.com
_blank">http://www.matronics.com/contribution
et="_blank">http://www.matronics.com/Navigator?KIS-List
ttp://forums.matronics.com
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[b]
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