After the Big Move, I spent 45 minutes last night moving things around and doing general organizing. I’m not sure if I know what the final arrangement will be, but I know “a big pile of crap” wasn’t it.
After 6 long years, and my poor project packed into a stirage unit, my name rose to the top of the hangar wait list last week. I spent the weekend re-situating the project into the hangar. Spent about 10 hours in total, but the storage unit is EMPTY and the hangar is (not quite) FULL!
Pictures soon, once I get things cleaned up, shelves assembled, etc.
Next step: inventorying the project!
After numerous attempts (nearly all leaks were through the fuel cap) the right tank has held air for 3 days w/o balloon leakage! I’m pronouncing this war won and moving on.
Yes, a hole appeared in the baffle…I coated the inside seams of the outboard rib with proseal. Re-riveted the baffle (it was being held together with clecos) and balloon tested…
Leak at the BNC connector for the resistance fuel gauge. Popped off the access panel on the inboard rib (it was held on with aviation gasket sealant) and smeared the backside of the BNC connector.
Finally, sealed up the tank with the allen screws Id bought from Grainger, and let the proseal set.
Testing today or tomorrow…
I found a leak in the seam of the outboard rib and leading edge. My poor balloon held air for a few moments before deflating to empty.
After drilling out the 250-300 rivets that held the baffle to the tank skins, I realized that drilling out the pop rivets that hold the z-brackets to the aft rib flanges would be a pain in the a$$. So after a little thought, I decided not to continue to remove the rear baffle.
So I gave in… I cut a rounded-rectangular hole in the baffle at the outboard end, to re-proseal the leading edge at the end rib seam, where the leak is.
I filed and scotchbrited the hole and a matching cover I made, the glopped a bunch of proseal along the inner seam. Unfortunately, there’s no way of knowing if I plugged the leak until the tank is sealed up again, so I’ll add a dollop of proseal to the rear corners of the outboard end of the baffle, just in case. Then we’ll seal it up and retest!
Leaking at the outboard rib of the right tank…auuugh!
It looks like I’ll try to go in through the filler hole with a few toothbrushes full of proseal. Unfortunately, I need to recruit a small-handed individual since mine are far too fat!
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