GasTank

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=100 BGCOLOR="#CCCCFF" TEXT="#080000" bgproperties="fixed" background="05b00640egdysm.jpg"> <div> <FONT SIZE="2" COLOR="#000066" FACE="Arial" ><B>Steve Kiblinger, .. Builder of a Milholland Better Half 2 cylinder VW and Legal Eagle Ultralight Airplane</B></FONT><FONT SIZE="5" COLOR="#000099" FACE="Arial" ><B> </B></FONT><B>    </B><B>   |     </B><A HREF="index.htm" TARGET="_top" TITLE="Steve Kiblinger, .. 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He has found another source of Klegacell  PVC foam:</I></div> <bR> <div> <I>Chuck Beason</I></div> <div> <I>11845 Loop 107</I></div> <div> <I>Adkins, TX  78101</I></div> <div> <I>Tel. (210) 649-1727</I></div> <bR> <div> <I>Call Chuck for pricing and delivery...</I></div> <bR> <div> <I>==================================================</I></div> <div> <B>We are going to use the Klegacell foam material because foam tanks don't sweat...The only water found in there will have to come from an outside source... We will use a layer of light glass inside for durability and assurance that none of the foam is eroding and traveling down stream ( this has happened in VariEze's)... We plan to run auto gas... The MTBE fuel additive is possibly being discontinued in California and we will use vinyl ester resin instead of epoxy for forward going durability if ethanol becomes the oxygenator...</B></div> <bR> <div> <B>When the left wing is assembled we will make cardboard patterns to optimize the tank space... </B><B>1/4 inch clearance will be provided on the tank sides and 1/2 inch on the top allowing for the downward mid-rib curve of the cover... To access the forward wing root attach hardware bolts the top right front corner of the tank as viewed from the cockpit has to be set back...The plans don't show a sump in the rear corner of the tank... The sump is there and commented on by Leonard in his video... [We have played his</B><A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U><B> </B></U></A><A HREF="http://www.betterhalfvw.com/" TARGET="_top" TITLE="http://www.betterhalfvw.com/"><U><B>Information video</B></U></A><B> several times and pick up something new each time thru]... The sump comes down to the cover on the wing bottom [Leonard drops the diagonal brace down on the face of the spar caps in this wing bay and puts plywood gussets on it to regain lost shear & racking strength]... We don't plan to cover the wing bottom joint over the pilot so the wing attachments can be inspected on each flight - we will occasionally take this plane apart and trailer...</B></div> <bR> <div> <B>We will remove the foam for 1 inch top to bottom of the tank on the inboard side and go glass to glass there... An inspection ring with a see thru cover will be put on the inboard end of the wing and a Lexan window in the bottom plywood area of the close spaced ribs giving the pilot access to visual fuel quantity status...</B></div> <bR> <div> <B>May 29, 2001 revision: </B><FONT SIZE="3" COLOR="#000000" FACE="Arial" ><B>We are making a cardboard mockup of the tank and using the cardboard pieces as Klegacell cutting patterns... We have limited the width of the tank to 12.33 inches... [We have not lowered the diagonal brace in our wing and with a cardboard mockup have sized the tank to go into the wing bay from the bottom with wide area washers on the 3 rear mounting bolts and extra glass around the rear lip - we are putting a quick drain at the rear of the sump also]... The sump will go a little past the bottom of the wing so drips will fall off the wing instead of running back to the trailing edge on the fabric... One layer of glass will be put on the inside of the tank before the pieces are floxed together... Peel ply will go on all inside surfaces that get a flox corner and tape when assembled... A 1 inch glass to glass sight gauge is located about 6 inches forward of the right rear corner - this must be located between the rib diagonal braces for best viewing from the cockpit thru a Lexan window on the bottom of the double ribs... </B></FONT></div> <div> <B>==============================================================</B></div> <bR> <DIV ALIGN="LEFT"></DIV> <div> <B>You'll need something like this roller...</B></div> <div> <B><IMG SRC="239f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>If you are using peel ply wet it thoroughly or it'll suck the glass dry...</B></div> <div> <B><U>Use wet micro balloon slurry between foam and glass for proper bond...</U></B></div> <div> <B><IMG SRC="21dfb7c0.jpg" border=0 width="507" height="380" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B><IMG SRC="21ff4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B><IMG SRC="221f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>1/8" 2024-T3 plate... Sand plate dull with #40 grit paper... Bed in flox...</B></div> <div> <B><IMG SRC="229f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>After the sump is finished inside and out nail the box together with 3/4 brads... Be sure they go right down the center of the 1/4" foam board... Pull misses out and repair with resin...</B></div> <div> <B><IMG SRC="22ff4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Run the taps back thru the outlets to clear excess resin and trial install the finger screen and quick drain... All corners are radius'd with wet flox...</B></div> <div> <B><IMG SRC="22df4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Be sure to scratch </B><B>the pipe </B><B>dull with #40 grit sandpaper and any other dry resin surface that is to get more resin... Tighten the cap and mark the pipe so the cap handles are oriented fore and aft... Make the sanding block shown from wood scrap and  spray on contact glue... Change paper by heating under shop light... Use flox on all assemblies... 1/8" 2024-T3 cap lid...</B></div> <div> <B><IMG SRC="231f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Pre wet any surface that is to get flox...</B></div> <div> <B><IMG SRC="233f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Sweep and vacuum the box clean before you close!...</B></div> <div> <B><IMG SRC="235f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>Tank has been pressure tested... Capacity measures 5.5 gallons in level condition... Site gauge has been calibrated... Front corner of tank relieved to give access to wing attach bolt... Nut plates have been installed... Site gauge will get another set of calibrations in parked condition later...</B></div> <div> <B><IMG SRC="23ef4130.jpg" border=0 width="500" height="275" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>We didn't lower the diagonal brace... The tank is slightly shorter and the rear lip has been reinforced with extra layers of glass tape (2 up 2 down 1 around the lip)... Nut plates are on the bottom of the lip with AN-3 bolts and wide area washers on top...</B></div> <div> <B><IMG SRC="240f4770.jpg" border=0 width="500" height="375" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <bR> <div> <B>We used 16 pound Klegacell foam that measures 1/4" thick...</B></div> <div> <B>The left wing is ready for cover...</B></div> </td> </tr></table></body>