Well done Bill, great alternative and well thought out.
Cheers,
Tim
Tim Ward
12 Waiwetu Street
Fendalton,
Christchurch, 8052
New Zealand.
ward.t@xtra.co.nz
Ph 64 3 3515166
Mob 0210640221
> On 21/03/2014, at 10:14 pm, bill <bill.sue@orcon.net.nz> wrote:
>
> 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 =C3=A9crit :
>>>
>>>
>>> Sue and Bill Sisley
>>>
>>>
>>> -------- Original Message --------
>>> Subject: Re: Europa-List: XS Fuel Tank
>>> 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 al
uminium fuel tank.
>>>
>>> After much deliberation I settled on 2mm aluminium to a design that elim
inated all the complexity of the plastic tank but increased the volume to 85
Ltrs. 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 a
nd one piece tunnel all flange welded for strength with cut-outs and insert
s to clear controls.
>>> I made the tank narrower that the previous to allow it to drop straight i
n without having to stretch the fuselage and 100mm taller for extra volume. N
o internal baffles were required as the tunnel and cut-outs provided suffic
ient rigidity.
>>> The outlets and breather are all AN fitings with provision for separate w
ater drains and fuel outlets left and right and the fuel return back to the i
nside of the starboard tunnel.
>>>
>>> The tank sits free with the bottom rear of the tank sitting on a flange o
ff 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 t
o the tank at all contact points preventing chaffing. The original spacers a
re 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 fu
rther to the rear.
>>>
>>> Fuel is measured with a capacitance probe calibrated in 1 litre incremen
ts.
>>> 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 som
e of the issues that I considered carefully before embarking on what turned o
ut to be a lengthy project.
>>>>
>>>> Capacity
>>>> If you want to maximise capacity, the tank shape will be complex to tak
e advantage of the available space. I went "full span" and put seamless tub
es through to accommodate pitch control and rudder cables. Since you have sa
wed 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 e
xtra 18 litres. Restore the strength of the CM joint using standard "good co
mposite 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. I
ncorporate supporting brackets to spread the (considerable) load to the fron
t and rear of the cockpit module (seat back). Design in some method of allow
ing 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 prev
ent pressure build-up and blow-back while filling. If possible use two, one o
n each side of the tank. I routed mine up and then down, venting under the f
uselage, 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 a
d-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 v
apourising 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 typ
e, if you only ever use one type of fuel, this won't be an issue. They can b
e used with a "lookup table" to linearize the readout giving an accurate ind
ication of fuel contents. Float switch stacks are the next option, (as suppl
ied by Europa) they are reliable and not fuel sensitive but give a non-linea
r indication. I opted for the former but included four optical sensors to gi
ve an independent indication of fuel contents at "Full", 2/3 1/3 and "Reserv
e" and chose to delete the standard "stand pipe", which, without any method o
f isolating, I considered a safety risk.
>>>>
>>>> Maintenance
>>>> Now is a good time to include an inspection hatch. Machine a large diam
eter "weld-in" ring with matching cover, tapped for at least six bolts. Incl
ude a groove to accept a Viton "O" ring to seal the joint. This cover also m
akes 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 t
he front of the tank where it sits on the mount. It appears that the fibregl
ass had bonded to the tank and with movement caused a fracture due to the st
ress. Having looked at the tank now which is very deformed and reducing capa
city, I am sure a "metal" one will be much superior. Fortunately there are s
ome very good craftsman around here so fabrication will not be a problem. No
t sure we will get to the same volume as you have but will certainly look fo
r 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 bu
ilt 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 fitting
s to accommodate alloy pipework. It is also fitted with a full length capaci
tive 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 a
nd perfect your cardboard templates - the fuselage is partly conical in sect
ion so the development will be an interesting shape. Choose a welder based o
n his ability to weld alloy and don't fall into the trap I did of restrictin
g 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 s
ure exactly where the fault is other than it is high up on the tank. Will kn
ow more when I get it out.
>>>>>>>
>>>>>>> My question to the forum is, has anyone tried fabricating a metal (a
luminium) tank rather than using the Polyethylene plastic one as supplied wi
th the kit. If so, were you able to obtain the same volume and any other adv
ice you may be able to offer.
>>>>>>>
>>>>>>> Many thanks
>>>>>>> XS Mono
>>>>>>> Kit 456
>>>>>>> 914 and Airmaster
>>>>>>> 1100hrs
>>>>>>>
>>>>>>>
>>>>>>> Sue and Bill Sisley
>
>
>
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