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Old 01-27-2019, 09:09 AM
dweyant dweyant is offline
Join Date: Sep 2012
Location: 07TS
Posts: 460
Default Rebuild left Fuel tank

I've finally had it with my left fuel tank leaking.

I've never been happy with it, so I'm just going to build a new tank.

I'm a much better builder (I think) than when I originally built them, so why not...

Anyway, I would appreciate any suggestions on the best way to do this to minimize down time. I'd like to build as much of the tanks as possible before I pull the old tank off the plane and replace it with the new one.

I have ordered all of the parts for a new tank from Van's and they should be here next week sometime.


Dan Weyant
Done and Flying 4/30/2015
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Old 01-27-2019, 09:54 AM
Greg Dillon Greg Dillon is offline
Join Date: Mar 2005
Location: Upland,California
Posts: 67

If you install a new fuel sender in the new tank instead of swapping out the original one replacing the tank is a one day affair, if that. Now this is with the assumption that all holes for mounting bolts and screws line up the same.....
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Old 01-28-2019, 07:44 AM
airguy's Avatar
airguy airguy is offline
Join Date: Oct 2006
Location: Garden City, Tx
Posts: 4,617

Originally Posted by Greg Dillon View Post
Now this is with the assumption that all holes for mounting bolts and screws line up the same.....
yeah, that's gonna be the trick right there - getting the holes drilled in the Z-brackets in the correct location is going to be the fun part.

I would entertain the thought of pulling the existing tank, then laying a piece of scrap aluminum or similar along the original Z-brackets, clamp it in place and backdrill the holes to the scrap with a right-angle drill, then transfer the scrap to the new tank and drill the new Z-brackets. That should get you reasonably close.
Greg Niehues - PPSEL, IFR, Repairman Cert.
Garden City, TX VAF 2019 dues paid
N16GN flying 400 hrs and counting! Built an off-plan 9A with too much fuel and too much HP. Should drop dead any minute now.
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