I read that the construction and sealing of the fuel tank could be a problem, so I approached the task with some concern. I envisioned black sealant all over my tank, my work bench, my tools, and my hands. Not a pretty thing to look forward to. However, the construction and sealing of the tank was not a problem at all. I just had to make sure every rivet and seam was sealed well.
The fuel tank holds 20 gallons of either premium auto gas or aviation fuel. This photo shows the front of the fuel tank with its mounting bracket at the bottom, and the fuel sensor at the right mounted to the sensor access cover.
This is the back of the fuel tank. It shows the back mounting bracket. You can see the fuel return line running across the top of the tank. It sticks up into the fuel filling tube (not shown).
The fuel level sensor mounts to the tank's access port, on the front of the tank. I hope I never have to break the seal to obtain access to the tank.
This photo shows the fuel level sensor on the right and the sensor float on the left. A visual float movement functionality check was necessary before the top of the tank was installed.
This shows the fuel tank sensor from the outside after installation. The electrical connection for the sensor is in the center of the plate.
The fuel tank floor is sectioned off into different compartments. The small corner at the front right of the tank is where the fuel is drawn from the tank by the fuel pump. It's designed so the fuel line is not starved of fuel when the plane is banking in a turn. The floor of the tank slants down to this corner so all the fuel in the tank can be used.
A little closer look at this corner shows the fuel filter screen and the return fuel tube that runs to the top back of the tank.
Once the tank was completely buttoned up, a leak test was performed, to make sure I didn't have any leaks before I dump fuel into it. A little pressure was applied to the tank through the return port, then monitored using a toy balloon on the outlet port. I was lucky because I had a tight tank... no leaks here!
On the back right of the tank is a visual window of the contents of the tank. The window can be used to verify the readings of the fuel sensor and to determine fuel levels during a sensor or electrical failure in an emergency.
This is the inside of the visual fuel level window. Care had to be taken to make sure the window was sealed to the side of the tank without any sealant covering the window ports. This was probably the most difficult part of tank construction.
The sealing and riveting of the top of the tank, with the filler tube attached, was the last step in the construction of the fuel tank. I'll be happy when the day comes I can put fuel in the tank and run fuel through my engine. Some day!!!
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