Model IV wing tank repair DIY.

[4Hummer]

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?"
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There be gold nuggets in these here tanks.
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[4Hummer]

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
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Into the Acetone 8:30pm
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14 Hours later...... Barely touched.. Time for Plan B:
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[4Hummer]

Wings have been taken home and prepped for surgery.

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

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Prepped and ready for surgery..
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This is what happens when you have diet high in ethanol

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It's a serious case of Ethanol-19

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Even the finger stainers were plugged.. How this was getting fuel I don't know, But so glad I decided to cut them open
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[4Hummer]

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

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Both tanks ready for some fibreglass repair

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[4Hummer]

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.

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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)
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Two layers of 1" tape on the Plexiglas
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EZ-POZY. did I mention how nice this stuff is?
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Lay Up.
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Needed more clothes pegs
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[4Hummer]

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

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Done:

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[Spook712]

This is how my right Tank looks inside.

I guess I‘ll try to get the coating out first, using acetone.


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[4Hummer]

Looks like its JUST the Kreem peeling off, you are in much better shape then I was

Good luck!

This is how my right Tank looks inside.

I guess I‘ll try to get the coating out first, using acetone.


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[afsalehimd]

My tank is doing the same thing. The Kareem is coming off.
How should I go about this? Do I need to cut out a window like you did or is there an easier solution?

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Looks like its JUST the Kreem peeling off, you are in much better shape then I was

Good luck!