The cost for the fabrication of the tank was $1230 NZ .
Finished weight about a Kilo more than the plastic tank.
Rgds
Sue and Bill Sisley
On 21/03/2014 8:08 p.m., Michel AUVRAY wrote:
> Hi Sue and Bill,
> It is nice job
> What is the price?
>
> Michel AUVRAY
> Builder 145
> 550 hours flight
>
>
> Le 21/03/2014 04:45, bill a crit :
>>
>>
>> Sue and Bill Sisley
>>
>>
>> -------- Original Message --------
>> Subject: Re: Europa-List: XS Fuel Tank
>> Date: Fri, 21 Mar 2014 16:35:46 +1300
>> From: bill <bill.sue@orcon.net.nz>
>> Reply-To: bill.sue@orcon.net.nz
>> To: europa-list@matronics.com
>>
>>
>>
>> A very happy day as ZK CHV is now back in the air complete with a new
>> aluminium fuel tank.
>>
>> After much deliberation I settled on 2mm aluminium to a design that
>> eliminated all the complexity of the plastic tank but increased the
>> volume to 85Ltrs. The structure was formed by a continuous fold from
>> the rear bottom and over the top to front bottom. The sides and
>> bottom are one fold each side and one piece tunnel all flange
>> welded for strength with cut-outs and inserts to clear controls.
>> I made the tank narrower that the previous to allow it to drop
>> straight in without having to stretch the fuselage and 100mm taller
>> for extra volume. No internal baffles were required as the tunnel and
>> cut-outs provided sufficient rigidity.
>> The outlets and breather are all AN fitings with provision for
>> separate water drains and fuel outlets left and right and the fuel
>> return back to the inside of the starboard tunnel.
>>
>> The tank sits free with the bottom rear of the tank sitting on a
>> flange off the rear wall of the cockpit module and the front sitting
>> on a full width flange off the front wall (seat-back) of the module.
>> A rubber pad is glued to the tank at all contact points preventing
>> chaffing. The original spacers are retained to prevent fore-aft movement.
>>
>> I raised the sides of the cockpit module to just level of the door
>> sills and continued the same angle for the head rests so they are now
>> slightly further to the rear.
>>
>> Fuel is measured with a capacitance probe calibrated in 1 litre
>> increments.
>> Reserve fuel on the starboard side is 14 litres.
>>
>> Some pics attached.
>>
>> Sue and Bill Sisley
>> On 12/11/2013 10:38 p.m., nigel_graham@m-tecque.co.uk wrote:
>>> Hi Bill
>>> If you are serious about constructing your own alloy tank, here are
>>> some of the issues that I considered carefully before embarking on
>>> what turned out to be a lengthy project.
>>>
>>> Capacity
>>> If you want to maximise capacity, the tank shape will be complex to
>>> take advantage of the available space. I went "full span" and put
>>> seamless tubes through to accommodate pitch control and rudder
>>> cables. Since you have sawed off the top of your cockpit module,
>>> there is now room to extend the tank vertically up by about 100 mm
>>> (to the door sill), this should give you an extra 18 litres. Restore
>>> the strength of the CM joint using standard "good composite practice".
>>> This should not compromise the seating or baggage-bay access.
>>>
>>> Mounting
>>> The tank cannot sit on the bottom of the fuselage but should be
>>> clear. Incorporate supporting brackets to spread the (considerable)
>>> load to the front and rear of the cockpit module (seat back). Design
>>> in some method of allowing the tank to expand and contract - sitting
>>> it on a rubber or cork mat for instance.
>>>
>>> Breathing
>>> Use considerably larger breathers than were originally fitted - to
>>> prevent pressure build-up and blow-back while filling. If possible
>>> use two, one on each side of the tank. I routed mine up and then
>>> down, venting under the fuselage, to prevent siphoning or fuel
>>> dumping in the event that the aircraft ever flipped over.
>>>
>>> Fuel Return
>>> I pondered the ideal configuration for the fuel return line
>>> (discussed ad-nauseum since!) and opted to return it to the top of
>>> the tank. A vertical cross-drilled pipe inside the tank allows the
>>> fuel to dribble down without vapourising or having to contend with
>>> the back-pressure of a full tank.
>>>
>>> Fuel Level Monitoring.
>>> There are now far more options available to accurately monitor the
>>> fuel contents. Capacitance level sensors work well but are sensitive
>>> to fuel type, if you only ever use one type of fuel, this won't be
>>> an issue. They can be used with a "lookup table" to linearize the
>>> readout giving an accurate indication of fuel contents. Float switch
>>> stacks are the next option, (as supplied by Europa) they are
>>> reliable and not fuel sensitive but give a non-linear indication. I
>>> opted for the former but included four optical sensors to give an
>>> independent indication of fuel contents at "Full", 2/3 1/3 and
>>> "Reserve" and chose to delete the standard "stand pipe", which,
>>> without any method of isolating, I considered a safety risk.
>>>
>>> Maintenance
>>> Now is a good time to include an inspection hatch. Machine a large
>>> diameter "weld-in" ring with matching cover, tapped for at least six
>>> bolts. Include a groove to accept a Viton "O" ring to seal the
>>> joint. This cover also makes an ideal mount for the fuel level sender.
>>>
>>> Good luck and keep us informed of progress.
>>>
>>> Nigel
>>>
>>>
>>> On 11/11/2013 22:43, bill wrote:
>>>> Thank you Nigel,
>>>>
>>>> Having got the top off now I can see that the leak is at the shelf
>>>> on the front of the tank where it sits on the mount. It appears
>>>> that the fibreglass had bonded to the tank and with movement caused
>>>> a fracture due to the stress. Having looked at the tank now which
>>>> is very deformed and reducing capacity, I am sure a "metal" one
>>>> will be much superior. Fortunately there are some very good
>>>> craftsman around here so fabrication will not be a problem. Not
>>>> sure we will get to the same volume as you have but will certainly
>>>> look for more than I have now. Will send some pic,s when all done.
>>>>
>>>> Regards
>>>>
>>>> Sue and Bill Sisley
>>>> On 12/11/2013 8:55 a.m., nigel_graham@m-tecque.co.uk wrote:
>>>>> Hello Bill,
>>>>>
>>>>> I'm a bit late getting back on this one but as others have said, I
>>>>> built a tank out of 5251 quarter-hard magnesium alloy.
>>>>> It weighs 7850 grams and has a capacity of 110 litres.
>>>>> I incorporated internal baffles, and breathers with proper AN
>>>>> fittings to accommodate alloy pipework. It is also fitted with a
>>>>> full length capacitive probe and four solid-state optical fuel
>>>>> level sensors.
>>>>> http://www.europaowners.org/main.php?g2_itemId=28719
>>>>>
>>>>> The only advice I would offer is: allow yourself a long time to make and
perfect your cardboard templates - the fuselage is partly conical in section so
the development will be an interesting shape. Choose a welder based on his
ability
to weld alloy and don't fall into the trap I did of restricting yourself
to a CAA approved welder whose self-belief exceeded his ability!
>>>>>
>>>>> Nigel
>>>>>
>>>>>
>>>>> On 08/11/2013 21:37, bill wrote:
>>>>>>
>>>>>> After 1100hrs I have suffered a failed fuel tank on my XS Mono.
>>>>>> Not sure exactly where the fault is other than it is high up on
>>>>>> the tank. Will know more when I get it out.
>>>>>>
>>>>>> My question to the forum is, has anyone tried fabricating a metal
>>>>>> (aluminium) tank rather than using the Polyethylene plastic one
>>>>>> as supplied with the kit. If so, were you able to obtain the same
>>>>>> volume and any other advice you may be able to offer.
>>>>>>
>>>>>> Many thanks
>>>>>> XS Mono
>>>>>> Kit 456
>>>>>> 914 and Airmaster
>>>>>> 1100hrs
>>>>>>
>>>>>>
>>>>>> Sue and Bill Sisley
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