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Submitted By:   elsa-henry@darlor-watch.com
Email List:   RV-List,RV3-List,RV4-List,RV6-List,RV7-List,RV8-List,RV9-List,RV10-List
Name:   

Henry Hore

Date:   

Sep 27 2003

Subject:   Corrosion Inside Fuel Tank Cap
Description:   

The photo shows what I found after removing the bottom half of a fuel tank cap installed in my RV-6A. I have 50 hours on it but the cap has been stored on the wings since they were constructed in 1996 (the kit was received with these caps in early 1995).

The problem arose when I tried to adjust the cap for a tighter fit. The stud that pulls the bottom half up to the top half to expand the O-ring is threaded into the bottom cap and locked with the 3/8"-24 jam-nut. To loosen this nut, I installed a hose clamp around the cap to prevent scoring it when I secured the cap in a vise This allowed loosening the nut which was very tight successfully. But there was no way I could turn the cap on the stud one way or another holding the latch lever in my hand. I had to use considerable force with the whole assembly clamped in the vice, which snapped off the roll-pins through the latch lever into the stud.

The photo shows the corrosion which prevented the cap from turning on the stud. At first, I thought that this was classic dissimilar metal galvanic corrosion, but I believe both parts are aluminum and there may be alloy differences that caused the corrosion in the presence water condensation which is evident elsewhere inside the cap?

I poured some GM penetrating oil liberally in the cap and let it sit for two days. I was finally able to loosen the stud and install a new roll-pin after cleaning-up the assembly.

 
    Fuel_tank_cap_2.jpg Corrosion Inside Fuel Tank Cap





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