Fuel Tank Construction and Installation

Mixing Micro balloons for the fuel tank joints and seams. This is one of the first sub assemblies I completed which was before I discovered the wonderful properties of milled fiberglass "flox" which is far superior to micro regarding structural applications and ultimate resistance to fuel. I made it a point to add two extra plies of the light weight glass cloth used to cover the fuel tank inside and out. I also made sure to apply the Aero-Poxy a little on the rich side to help combat any leaks that may occur. I am also planning to use a fuel tank sealant. I have to order the proper sealant from Aircraft Spruce and Specialty.

Front Closeout Section of Fuel Tank.

Front section of tank after glassing and before removal of plastic sheet.

Sanding the Bottom Section of Fuel Tank in preparation for glassing..

Bottom of tank after removal of top layer of glass and foam core to create the V shape.

Bottom view of Fuel tank seam.

Preparing to lay fiberglass cloth to the inside of the bottom section of tank.

Creating a micro filet on the bottom and rear seams of the fuel tank.

Miro cured, sanded, and ready for glassing of seams.

Drying and setting of Pre-cured glass strip on the front leading edge of fuel tank that is to be bonded to the front closeout of the tank.

Close up of the pre-cured glass strip with micro filet.

Applying two layers of 3 oz.Fiberglass over post cured and sanded micro filet.

Micro filet curing on bottom of tank joint.

All three sections of fuel tank glassed. Micro Curing on Bottom section.

Outside bottom of fuel tank being prepared for application of glass seam.

Dry fitting lower section of fuel tank and marking outer edges where the top of tank will receive two layers of 3 oz. glass cloth. Fuselage is inverted in this photograph.

Sanding the cured micro for glassing of two layers of 3 oz cloth over filet.

Preparing 3 oz. glass cloth to be installed on the top section fuel tank.

Kicking ass and laying glass. You will notice the lip already has it's micro filet on both side to insure no air bubbles are trapped under 3 oz. glass layup.

Top of header fuel tank marked where the 3 oz. glass layup will be installed. Fuselage is inverted in this picture.

Per instructions, joining flange sanded to remove lip/ridge and micro filet applied on either side in preparation for 3 oz. glass liner.

Smoothing out the cured micro filet.

"Tacking Fuel Tank into place with dabs of fast micro.

Installing micro balloons for fuel tank installation.

Bottom of fuel tank repair from a accidental slight cut that occurred during handling.