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Locating fuel tank holes in skins?

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a.s.elliott(at)cox.net
Guest

Posted: Sat Jun 09, 2007 11:57 am Post subject: Locating fuel tank holes in skins?

Folks:

  

 I received by quick-built wings with the top skins and top of leading  edges fully riveted and the bottom skins and bottom of leading edges  tacked.  (Yes, this seemed backward to me when I got them, but that's how  they are.)  There are no pre-machined holes in the skins for the fuel tank  inlets, drains and vents, so I will need to locate and make the holes, before  installing the tanks and closing the wings. 

  

 The method in the photo guides assumes that the *top* leading skin is  loose.  Anyone have an especially good idea or method for doing this with  the wings like I have them?

  

 Thanks,

 Andy Elliott, Mesa, AZ

N601GE (reserved)

601XL/TD/QB, Corvair,  building...

  

  

   [quote][b]

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craig(at)craigandjean.com
Guest

Posted: Sat Jun 09, 2007 12:35 pm Post subject: Locating fuel tank holes in skins?

For the items that  penetrate the lower skin you should be able to use the same template  approach that Zenith uses for locating the fuel cap in the top skin (although  the template wouldn't have to be  transparent):

  

 See page three  here:

 www.zenithair.com/zodiac/xl/data/6k1.pdf

  

 1. use a piece of  template material that reaches from the vent or drain to a rivet line on the rib  or spar

 2.  fit the tank  into the wing with all the cork in  place.

 3. make a hole in  the template to align with the vent or  drain

 4. back-drill or  use a rivet-hole copier/duplicator top make the rivet holes in the  template

 5. remove the  tank

 6. temporarily  close the bottom skin and drill the skin-to-rib rivet  lines

 7. Cleco the template  in place and transfer the vent or drain hole  position.

  

 You will have to  change the order a bit if the rib rivet holes weren't drilled at the  factory.

  

 --  Craig

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dredmoody(at)cox.net
Guest

Posted: Sat Jun 09, 2007 1:01 pm Post subject: Locating fuel tank holes in skins?

Andy, this is going to sound overly complicated but  I think it will get you out of  the corner that the factory painted you  into. First, take the tank out onto the workbench and use a hole saw (of  whatever size works) to produce a round plug of 3/4" pine or spruce wood a bit  larger than the threaded filler neck female that is welded into the tank top  skin. Then work the plug into a bevel along its sides (ue a belt sander) until  it fits almost flush with the top of the threaded female but is still too tight  to get pushed clear into the tank. If you think you have sanded too much and the  plug might push into the tank wrap it with paper until it is too tight to fall  into the tank. If it does fall in, the world is not lost; you can retrieve it  through the fuel level sensor hole on the inboard end later. 

  

 Okay so now you have a round wooden plug that fits  tight in the filler hole, right? And since you made it with a hole saw it has a  1/4" hole in its center. Now you take a 1/4" bolt, with two washers and two  nuts. Get on a bench lather (grinder) and sharpen one end of the bolt so that it  has a point like a punch or an awl. Set the bolt through the hole in the wood  with the pointed end facing out. Set the plug in the tank, set the tank in the  leading edge, wrap the skin down snug and with a piece of plywood on the top LE  skin, tap on the plywood with a hammer until the sharpened bolt marks the center  of your hole for you.

  

 Happy now?

  

 Dred

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JohnDRead(at)aol.com
Guest

Posted: Sat Jun 09, 2007 3:39 pm Post subject: Locating fuel tank holes in skins?

Andy, Dr Ed's advice is good. I would check one other thing. I am not  familiar with the fast build kit so I do not know if all of the  tank locating brackets etc are in place, also the cork needs to be in place  so the tank is firmly located in the wing.

  

 John Read



See what's free at AOL.com. 

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