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Date: Tue, 02 Jan 2007 16:17:37 -0500
From: Ernest Christley <echristley@nc.rr.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Re: Yet another limp home story
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James Maher wrote:

> Ernest,
> I have been considering several ways to build the tank from alum sheet.
> I think that I have settled on the following design:
> A one piece sheet that starts at the top front and goes down from 
> there to the front bottom,
> then back along the frame, then up towards the vert fin, then back to 
> the top front with a flange to weld the sheet at the top front.
> This will allow the insertion of flanged baffles just as in the F.G. 
> tank that can be welded in and then flanged end caps can be welded 
> in to seal the tank on the sides.
> This method would have one weld along the top front and then around 
> each side plate.

You'll leave a lot of fuel capacity in the sides, unless you complicate 
the design to add a large flange to the top corners that will fit around 
the curve.

> Of coarse there will also be a sump in the bottom of the tank just as 
> I have in the F.G. tank.

I'm hoping the .040 5052 will stretch enough to make a sufficient sump, 
but I'll have to test it first.  The question I have is how to route a 
drain line to be able to drain the tank for preflight?  Everything I've 
been able to picture means either crawling around under the plane before 
each flight, or having a drip prone drain filling the INSIDE of the 
airplane with gas fumes.  Neither picture is pretty.  How did you handle it?

>  
> I'm not sure how you would be able to include the baffles with your 
> method unless you were not going to attach them to the top, but you 
> have probably already figured it out.

Rivet the baffles in the bottom, front and back before welding the 
top/side flange.  Weld over them afteward.    The top/sides piece will 
be a flat sheet with two large curves.  It should be a simple matter to 
start from the center and rivet it down.  Just like closing up a wing.

-- 
         ,|"|"|,              Ernest Christley       |
----===<{{(oQo)}}>===----    Dyke Delta Builder      |
        o|  d  |o        http://ernest.isa-geek.org  |