Wingtip
Tank Conversion
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I used Derakane vinyl ester resin, as
this is impervious to fuel and chemicals.
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The inside of the stock tips must be sanded then coated with
Derakane.
·
You need a sheet of aluminum, SS or
galvanized metal.
·
Wax this sheet well.
·
Mark out wing profile using heavy
cardboard.
·
Use wing profile template to
spread/compress tip into proper position. (This is critical if you want it to
fit onto your wing later)
·
Support tip into this position using
tape, sticks, etc.
·
Use heavy cardboard and a scribe to
determine the size and shape of all baffles.
·
Use your new cardboard templates to
mark & cut fiberglass cloth (be generous, they can be trimmed later)
·
Add extra layer of cloth in center of
main inboard sealing baffle (approx. 6" round) for penetration point of
fuel & vent lines.
·
Lay cloth layers onto waxed sheet.
·
Wet out cloth, removing all bubbles.
·
After curing, peel of sheet metal
& trim excess.
·
Fit baffles into position, trimming
until they fit snug without distorting tip shape/wing profile.
·
Glass into position, using wetted
pieces of cloth.
·
Last baffle at trailing edge should be
sealed to prevent fuel from going past into trailing edge (approximately where
aluminum rib fits in)
·
If tip lights are used then a sealed
baffle is also required at leading edge (approx. 6" aft)
·
To additional baffles should be in the
center section, with approx. 2" transfer holes.
·
Install fuel cap & drains at the
Hi/Low (on ground) points depending on TD or TG. Use proseal.
·
Fit main sealing baffle to tank being
careful to trim to wing profile. This should sit 3/4" to 1" deep into
the tank.
·
Install bulkhead fitting for fuel
& vent, into reinforced area. Use proseal to seal fittings.
·
Run internal fuel & vent lines to
Hi/low (in flight) spot. Anchor these by running them through the internal
baffles.
·
Glass main baffle into tank.
·
Install a 1/2 strip of .032 aluminum
into joint lip of tip tank for reinforcement.
·
Install nutplates for attachment to
wings.
·
Leak test
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Attach & plumb into fuel system.
I guess I should throw in the usual disclaimers, about responsibility. As a matter of fact, you would probably be better off to not listen to anything I have to say, just stay at home on a nice safe couch. If you have no fiberglass experience you might want to buy a book or two, maybe take a course and practice some. Then if you still enjoy it you've probably inhaled too many fumes. Good luck.