---------------------------------------------------------- Europa-List Digest Archive --- Total Messages Posted Sat 03/22/14: 2 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 12:26 AM - Re: Fw: Re: XS Fuel Tank (nigel_graham@m-tecque.co.uk) 2. 08:31 AM - Re: Re: XS Fuel Tank (Andrew Sarangan) ________________________________ Message 1 _____________________________________ Time: 12:26:35 AM PST US From: "nigel_graham@m-tecque.co.uk" Subject: Re: Fwd: Re: Europa-List: XS Fuel Tank Bill, Congratulations on a fantastic result. Your tank looks well thought-out and beautifully constructed. You should be justifiably proud of a job well done. I can only look at those lovely flat panels and neat welding with envy :-( I would love to see some more pictures of this, either on or off list (though I suspect that a lot of people will have an interest in this). Nigel > -------- Original Message -------- > Subject: Re: Europa-List: XS Fuel Tank > Date: Fri, 21 Mar 2014 16:35:46 +1300 > From: bill > To: europa-list@matronics.com > > > Snip .... > A very happy day as ZK CHV is now back in the air complete with a new > aluminium fuel tank. > > > Sue and Bill Sisley > ________________________________ Message 2 _____________________________________ Time: 08:31:46 AM PST US From: Andrew Sarangan Subject: Re: Re: Europa-List: XS Fuel Tank Great looking fuel tank. Hopefully this will also simplify the static discharge issue. On Thu, Mar 20, 2014 at 11:45 PM, bill wrote: > > > Sue and Bill Sisley > > > -------- Original Message -------- Subject: Re: Europa-List: XS Fuel Tan k Date: > Fri, 21 Mar 2014 16:35:46 +1300 From: bill 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 volum e > 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 fo ld > 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 i n > 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 i s > 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 increment s. > 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 exten d > the tank vertically up by about 100 mm (to the door sill), this should gi ve > you an extra 18 litres. Restore the strength of the CM joint using standa rd > "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 o f > 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 preven t > 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 > 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 do wn > 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 fou r > 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 bolt s. > 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 hav e > but will certainly look for more than I have now. Will send some pic,s wh en > 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 capaciti ve > 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 sectio n 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 restrictin g yourself to a CAA approved welder whose self-belief exceeded his ability! > > Nigel > > > On 08/11/2013 21:37, bill wrote: > orcon.net.nz> > > 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 kno w > 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 suppli ed > with the kit. If so, were you able to obtain the same volume and any othe r > advice you may be able to offer. > > Many thanks > XS Mono > Kit 456 > 914 and Airmaster > 1100hrs > > > Sue and Bill Sisley > > ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message europa-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Europa-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/europa-list Browse Digests http://www.matronics.com/digest/europa-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.