May 21, 2016
* The wire for the elevator trim tab running along the Horizontal stab into the fuselage needed a connection added so that the elevators could be removed easily. I found a mini 5 wire Molex connector that worked just right. It isn't waterproof though so I may have to change it for something else.
* Finally installed all of the flush screws that hold the elevators on. I may change them for the next size shorter though.
* The highlight of the day was getting the fuel tanks fitting into the wings, AND BACK OUT AGAIN! The tanks needed sanding along the lid edge. Broke through in a few places and found that the sealing glue does not go all the way up the flange, only along the bottom. The tank walls are very wavy. I think the fabricator could do a better job of making these. The interior of the fuselage got most of the sanding to knock down some of the lumps and bumps. To find where it was needed I sprayed gray primmer paint on the tank edges then slid it in as far as it would go. The paint marks the areas that are rubbing. This was a very repetitive process for both tanks but it worked and the tanks go in and out, albeit with some effort. To pull on the tanks for removal I installed the finger strainer and an elbow. I then wrapped a rope around the fitting to pull with. The bonded fitting in the tank seemed OK with this. I can't pull hard enough to hurt it. It took a lot of work to get to this point. My knees hurt from sanding inside the wing to get the tanks to fit. The wings are on saw horses and being on my knees is the best way to reach inside. Some hand sanding and some power sanding did he job.
* Once the tanks were functional the fuel filler position was measured on the tanks and marked on the wings. The plans are pretty good but call for 64" from the wing root and our measurements (multiple times) came out to 65". 64" would have put the filler ring's flange on the recessed step of the tank and would not have seated well. The ring was floxed onto the tanks and the tanks slid back into the wings. Once in position the outer filler ring was screwed into the tank ring and left to set up. A 2 1/2" hole saw was used to cut both holes. It is the perfect size for the wing skin hole and a bit under for the tank hole. The tank hole was sanded out a bit to fit the ring. This was easy to do.
*** I had lots of help from Lloyd so when the job was done We had beers to celebrate.
It's a very tight fit. The rear bulkhead is where most of the interference was.
Very tight along the upper wing skin
Measured 3 or 4 time before making the cut. A 1/8" pilot hole was made thru wing and tank to reassure this was the place.
I am cutting a 2 1/2 hole in the left wing
Since the outer ring is only there to align the tank ring it is not necessary to line up the tabs yet.
Thanks for the help Lloyd. You helped me double check everything before cutting and boosted my confidence in what I was doing. Finally something I didn't have to do twice.