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Thread: Model IV wing tank repair DIY.

  1. #1

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    127

    Default Model IV wing tank repair DIY.

    Figured I start a thread over here and not just one on Facebook (where it will never be found again)

    This is a 1992 era Kitfox IV, built in 1995, I'm the 3rd owner, I purchased this in October 2019,

    I completely rebuilt the plane and had it ready for spring, then well COVID hit, and I couldn't get my tail dragger endorsement. Finally the restrictions where lifted and she went on her maiden flight by my instructor... Flew great, but started leaking fuel out the carbs when it landed, Since the carbs were pretty much the one thing I didn't rebuild when I bought it I had them done, (Sonic bath, all new parts, rebalanced and sync'd) Plus I had a McFarlane throttle added (I hated the stock throttle... wouldn't always go back to idle and stay there)

    At this point we noticed some crap in the gascolator (yellow chucks), and I suspected the tanks.

    My original plan was to take the wings off, and re-slosh the tanks

    What I discovered however led me down a totally different path.

    This the wing in the rotisserie you could hear crap sliding around inside the tank.

    This Picture is my instructing pointing the gas filler neck saying "I Flew that thing?"
    120478360_10158287163104927_4587934888767754844_o.jpg

    There be gold nuggets in these here tanks.
    120356856_10158287162639927_3969418089458281787_o.jpg

    120553443_10158287163949927_8683142970515892087_o.jpg

    120500015_10158287164649927_526786931818247650_o.jpg

  2. #2

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    127

    Default Re: Model IV wing tank repair DIY.

    I had hoped I could clean the tanks out with acetone and reslosh them so I soaked some smaller chunks in a jar of acetone to see how long this stuff takes to dissolve, (Little science experiment)

    Test Subject
    120364025_10158287181149927_4560487357079953928_o.jpg

    Into the Acetone 8:30pm
    120529396_10158287181679927_5246549214052864771_o.jpg

    14 Hours later...... Barely touched.. Time for Plan B:
    120605438_10158288134864927_3526948305250408681_o.jpg


  3. #3

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    127

    Default Re: Model IV wing tank repair DIY.

    Wings have been taken home and prepped for surgery.

    Cut lines, Hoping to avoid cutting threw one of the reinforcement ribs.

    120936779_10158300559379927_8727194245719433965_o.jpg

    Prepped and ready for surgery..
    121057160_10158301665174927_2254294563957657399_o.jpg

    This is what happens when you have diet high in ethanol

    120997744_10158301674614927_2415011807340350906_o.jpg

    It's a serious case of Ethanol-19

    121011380_10158301675069927_3693460663455811795_o.jpg

    Even the finger stainers were plugged.. How this was getting fuel I don't know, But so glad I decided to cut them open
    120780999_10158301676149927_2179721168733076497_o.jpg

  4. #4

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    127

    Default Re: Model IV wing tank repair DIY.

    Dremel Multi Tool with the Diamond grit sanding pad for the win. This tool made short(ish) work of things. and doesn't clog up like sand paper

    121057821_10158302617159927_333664832244953284_o.jpg

    Both tanks ready for some fibreglass repair

    120995846_10158302625009927_684002047850992074_o.jpg

  5. #5

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    127

    Default Re: Model IV wing tank repair DIY.

    Little trip to Aircraft Spruce.

    EZ-Poxy I have to say is the nicest low odour. easy to use, easy to clean up resin I have ever used. Fuel and Ethanol safe.

    121134299_10158304716739927_123628571356812290_o.jpg

    Fibreglassing a new lip to seal the top
    Started by cutting 2" strips up some super thin plexi sheets I had. (Note the Fiberglass tape is 1" wide)
    121108293_10158304718329927_4843331916523637239_o.jpg

    Two layers of 1" tape on the Plexiglas
    121136094_10158304720329927_2756127488199998277_o.jpg

    EZ-POZY. did I mention how nice this stuff is?
    121090745_10158304722204927_659014336215780062_o.jpg

    Lay Up.
    121092788_10158304723154927_5033044423837005397_o.jpg

    121121656_10158304723639927_3983512023518799877_o.jpg\

    Needed more clothes pegs
    121107123_10158304724359927_6446553604828909035_o.jpg


  6. #6

    Join Date
    Oct 2018
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    Kitchener, Ontario
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    127

    Default Re: Model IV wing tank repair DIY.

    Had to let that set up overnight, I had the Heat in the garage on high (25c/77f)
    Next we need to add a lip to the stiffener ribs you'lI have to cut threw

    121114464_10158304724824927_8434724344939778474_o.jpg

    Done:

    121571480_10158319468894927_7634861561741911964_o.jpg

  7. #7

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    127

    Default Re: Model IV wing tank repair DIY.

    Here is the Tank sealer. (sitting on the cut out of one of the tanks.. )


    Aircraft Spruce Part Number: 09-03477
    https://www.aircraftspruce.ca/.../gastanksealer.php...
    121552319_10158319469239927_3533182653762415341_o.jpg

    Close up of the Ribs, I ended up leaving a fair amount of the old epoxy that was glued to the baffles, as it helps line everything up. (Removed all loose crap first)

    121436107_10158319496129927_4989768545987468580_o.jpg

    First Coat Lids
    121484429_10158319521639927_6002472355124842942_o.jpg

    121555873_10158319521389927_6015832552379187622_o.jpg

    Tank Bare.
    122003756_10158328690469927_2491072473123831052_o.jpg

    Tank 1st coat:
    122027420_10158328691614927_4124091257269481523_o.jpg

    2nd Coat; FYI it takes 2 Quarts to seal both tanks.
    122073237_10158329843329927_2597414597611667049_o.jpg

  8. #8

    Join Date
    Oct 2018
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    Kitchener, Ontario
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    Default Re: Model IV wing tank repair DIY.

    Sanded off 1/2" of the Gel Coat all the way around the top of the tank, and the lid, This is to prep for sealing the lid back to the tank. A 1" Fibreglass tape will be glued to the top once the lid is glued down internally

    122066371_10158329849844927_1914750540907513073_o.jpg

    The Lid
    122086856_10158329852369927_3024830628883415358_o.jpg

    I mixed the epoxy with Micro Ballon's into a couple different consistency. 1st Coat Very thin to brush along the edges, 2nd a bit thicker to fill some of the voids. and 3rd extremely thick to re-glue the baffles to the lid.

    122270658_10158331952044927_8231842182388007492_o.jpg

    One Lid Glued down. Will need to wait a couple days before doing the other as I have run out of things to place on top to get that perfect seal.

    122141282_10158331947114927_9009544395136254669_o.jpg

    I'm pretty impressed with myself. One lid back on. (Weights removed)
    122164603_10158335067819927_6659432498141457288_o.jpg

    seams came out real nice too. This is after a bit of sanding
    122341158_10158335069334927_8095255743348129959_o.jpg

    Added a 1" top layer of tape over the seam. (might be overkill.... but...)

    Tomorrow I hope to glue the lid on the other wing. Just need a hand moving it off the rotisserie, and putting this wing into it.

    122229224_10158335073154927_3732682724025445654_o.jpg





  9. #9
    Senior Member bbs428's Avatar
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    Jan 2015
    Location
    SW Missouri
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    649

    Default Re: Model IV wing tank repair DIY.

    Very interesting thread. That is some serious work. Unbelievable the chunks that were in the tanks. Sure is looking good now!

    All the best getting it all done.
    Somebody said that carrier pilots were the best in the world, and they must be or there wouldn't be any of them left alive. — Ernie Pyle

    Brett Butler
    Flying: 1998 Model 5 Outback, 912ul Zipper 110hp, G3x avionics, ss7 upgrades

  10. #10
    Senior Member
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    Dec 2017
    Location
    Mapleton,UT
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    1,224

    Default Re: Model IV wing tank repair DIY.

    Crazy what was in your tanks. So is the yellow chunks resign from the tanks?
    Dustin Dickerson

    Building 7ss STI x 2
    Oratex
    29" shock monster
    EP912STI 155hp
    Garmin
    N33TF......FLYING!
    N53TF......FLYING!

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