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Fuel tank caps for 601XL

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rhaskins(at)kumc.edu
Guest

Posted: Thu Jun 26, 2008 6:10 pm Post subject: Fuel tank caps for 601XL

My building partner and I have discovered that the fuel tank caps that Zenith sent when screwed on do not sit flush with the wing. Apparently the vendor that sent the caps changed them without notifying Zenith. Zenith will not offer any help other than telling us to find out what other builders are doing to correct the problem. Has anyone else had this problem, and does anyone know of a fix? Thanks.

ding(at)tbscc.com
Guest

Posted: Thu Jun 26, 2008 6:38 pm Post subject: Fuel tank caps for 601XL

Robert,

              Are the caps bottoming out on the welded tank bung before the  outer flange meets the skin?  

                                                                                                                         Lynn                         Corry, PA

    [quote][b]

dbrown(at)avecc.com
Guest

Posted: Thu Jun 26, 2008 8:43 pm Post subject: Fuel tank caps for 601XL

I had the same problem on one tank.  I took a dremel tool with a metal cutting bit and cut a 45 degree countersink about 3/16”  all the way around.  It wasn’t easy, but I did it without messing up the threads.  

   

David  N601EX  

--

Iberplanes

Joined: 10 Dec 2007
Posts: 174
Location: Igualada - Barcelona - Spain

Posted: Thu Jun 26, 2008 11:36 pm Post subject: Fuel tank caps for 601XL

After checking my tanks, I found the same problem here. My kit was made in nov 07. 



Any ideas? 



-- 

Alberto Martin

www.iberplanes.es

Igualada - Barcelona - Spain

 

----------------------------------------------

Zodiac 601 XL Builder

Serial: 6-7011



Tail Kit: Finished

Wings: Not Started

Fuselage: Ordered

Engine: Jabiru 3300  [quote][b]

_________________
Alberto Martin
601 XL - Jabiru 3300
http://www.iberplanes.es
Igualada - Barcelona - Spain

Afterfxllc(at)aol.com
Guest

Posted: Fri Jun 27, 2008 12:19 am Post subject: Fuel tank caps for 601XL

Mine are from 4/17/08 and I don't see a problem with them. Could you post a  pic of them so I can see what you are referring to?

  

 Jeff



Gas prices getting you down? Search AOL Autos for fuel-efficient used cars.

ding(at)tbscc.com
Guest

Posted: Fri Jun 27, 2008 2:51 am Post subject: Fuel tank caps for 601XL

My kit was Feb., 2006  manufacture. I understand Zenith later started welding the threaded bung on the  bottom side of the skin to lower it. I did the countersink job as well, and was  careful with the threads. I needed more, and drove the bung down (bending the  tank top skin) with a block of wood and a mallet. Worked very well, and allowed  me to level the bung to be parallel with the top of the leading edge skin  as an extra benefit.  Use great caution not to let the filler threads gall  or crossthread when installing the cap socket, it can happen very easily with  the fine threads and direct alum. to alum. contact. I used antisieze compound  after almost "sticking" one while fitting it. I also bought Baker Seal from ACS  for the final installation, as it has antisieze properties in addition to  sealing, but still allows future removal.

                                                                                                       Lynn Dingfelder

                                                                                                       601XL /  Corvair       done -- starting to  paint

    [quote][b]

rhaskins(at)kumc.edu
Guest

Posted: Fri Jun 27, 2008 6:54 pm Post subject: Fuel tank caps for 601XL

I didn't do a good job of describing the problem. The reason that the caps are not flush with the skin is that the filler tubes, which are screwed into the tanks do not screw down far enough. The filler tubes have a beveled shoulder at the top, and the top of the tanks are not beveled. The cap and top of the filler tube extend each extend up beyond the outer skin

sperry50(at)comcast.net
Guest

Posted: Sat Jun 28, 2008 4:52 am Post subject: Fuel tank caps for 601XL

Sounds like you need to call Zenith and get the “giant counter-sink”. Also, don’t forget the tap to clean the threads after you’ve done the counter sink.  

Skip Perry  

Do not archive  

         

  

From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Robert Haskins

 Sent: Friday, June 27, 2008 10:51 PM

 To: zenith-list(at)matronics.com

 Subject: Re: Fuel tank caps for 601XL  

  

   

I didn't do a good job of describing the problem. The reason that the caps are not flush with the skin is that the filler tubes, which are screwed into the tanks do not screw down far enough. The filler tubes have a beveled shoulder at the top, and the top of the tanks are not beveled. The cap and top of the filler tube extend each extend up beyond the outer skin  

     &7~	2,gSS  [quote][b]

pavel569

Joined: 21 Dec 2007
Posts: 77

Posted: Sat Jun 28, 2008 4:52 am Post subject: Re: Fuel tank caps for 601XL

Picture worth thousand words.

 	  rhaskins(at)kumc.edu wrote: 	
		  I didn't do a good job of describing the problem. The reason that the caps are not flush with the skin is that the filler tubes, which are screwed into the tanks do not screw down far enough. The filler tubes have a beveled shoulder at the top,ï¿½and the top of the tanks are not beveled. The cap and top of the filler tube extend each extend up beyond the outer skin

_________________
Pavel
CA
Zodiac 601XL
Stratus Subaru EA-81
Tail, flaps, ailerons, wings, fuselage, canopy done ...
"do not archive"

Afterfxllc(at)aol.com
Guest

Posted: Sat Jun 28, 2008 9:44 am Post subject: Fuel tank caps for 601XL

I looked at my tanks and they are the same as the older kit I built a year  ago. I think he has too much cork under the tanks and the top is too close to  the skin. Most times I have to put 2 and sometimes 3 layers of cork around  the filler neck to make the cap even with the skin. I'm sure some will remember  the trouble with the filler neck not laying flush. I wish he would send a pick  of the tank in the wing. 

  

 Jeff



Gas prices getting you down? Search AOL Autos for fuel-efficient used cars.

rhaskins(at)kumc.edu
Guest

Posted: Sat Jun 28, 2008 8:22 pm Post subject: Fuel tank caps for 601XL

Here are photos of the fuel neck with the cap on. It shows the bevel or flange at the top of the fuel neck, but there is no corresponding bevel in the top of the fuel tank hole. It screws in, but stops at the bottom of the flange.

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Aerolitellc(at)aol.com
Guest

Posted: Sun Jun 29, 2008 12:17 am Post subject: Fuel tank caps for 601XL

Looking at your pics my hunch was correct... you have the skins too close  to the tank. I have the same caps you do and if you only use one row of cork on  the bottom you will have close to a 10 to 12 mm  gap between  the tank and the top of the skin then you build around the filler neck with  a couple of layers of cork to make up the difference and to level out the top of  the neck. I will be building mine in a week and it takes me 2 weeks to finish  them so I will post some pics on my web site.

  

 You can call if you need anything else 502-644-8123

  

 Jeff



Gas prices getting you down? Search AOL Autos for fuel-efficient used cars.

zenithlist(at)yahoo.com
Guest

Posted: Sun Jun 29, 2008 2:07 pm Post subject: Fuel tank caps for 601XL

So what is the proper number of cork layers between the top of tank and top leading edge skin?  How about between the bottom of tank and bottom of leading edge skin?

--- On Sun, 6/29/08, Aerolitellc(at)aol.com <Aerolitellc(at)aol.com> wrote:

  	  Quote: 	
		  From: Aerolitellc(at)aol.com <Aerolitellc(at)aol.com>

Subject: Re: Fuel tank caps for 601XL

To: zenith-list(at)matronics.com

Date: Sunday, June 29, 2008, 1:12 AM

  Looking at your pics my hunch was correct... you have the skins too close to the tank. I have the same caps you do and if you only use one row of cork on the bottom you will have close to a 10 to 12 mm  gap between the tank and the top of the skin then you build around the filler neck with a couple of layers of cork to make up the difference and to level out the top of the neck. I will be building mine in a week and it takes me 2 weeks to finish them so I will post some pics on my web site.

 You can call if you need anything else 502-644-8123

 Jeff

   Gas prices getting you down? Search AOL Autos for fuel-efficient used cars.

 	  Quote: 	

          [quote][b]

Afterfxllc(at)aol.com
Guest

Posted: Sun Jun 29, 2008 2:23 pm Post subject: Fuel tank caps for 601XL

I think if I remember correctly it was 1 layer on the bottom is all and  more at the top. In other words just as much as needed on the bottom to keep it  from touching the skins. Also make sure your vent isn't holding the tank forward  and off the spar. Like I said you can call if you like.

  

  

 Jeff



Gas prices getting you down? Search AOL Autos for fuel-efficient used cars.

Ron Lendon

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

Posted: Sun Jun 29, 2008 2:55 pm Post subject: Re: Fuel tank caps for 601XL

While you're waiting, take a look here and maybe get some ideas.



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



I think I was doing this sometime around the 8th month of 2007 if you want to look it up in the kitlog.

_________________
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/

rhaskins(at)kumc.edu
Guest

Posted: Mon Jun 30, 2008 7:17 am Post subject: Fuel tank caps for 601XL

Thanks everyone for the help. We are in the process of moving everything to a new workshop.Unfortunately, it won't make me any smarter. We put two layers of cork under the tank. I am anxious to get everything "unbuttoned" and try again.  Thanks again.

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