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Assembling
the Fuel Tanks
Feb 24, 2002
Drilled Tank skin holes to size 2.0 hrs
Feb 25, 2002
Started countersinking the tank skins to rear baffle holes 1.0 hr
March 2, 2002
Finished countersinking the tank skins to rear baffle holes. Started fabricating
the T-405 tank attach angles. 2.0 hrs.
March 3, 2002
Finished the T-405 tank attach angles and finished the T-410 Reinf. plate. Did
both RH and LH parts. 4.0 hrs 
March 10, 2002
Started working on the Capacitive fuel probes 1.5 hrs March
13, 2002
More work on the Capacitive fuel probes 1.5 hrs March
16, 2002
Finished all that I can do with the Capacitive fuel probes until I start sealing
the tank. Drilled fuel cap and drain to skin. made Vent line clip. 4.5 hrs 
March
17, 2002
Worked on the Root Rib Access panel and ring, drilled hole for the vent line
fitting and BNC connector. When you drill the hole for the vent line be sure to
allow enough room for the Large washer. In the picture below the anti rotation
bracket is made but not installed yet. 4.5 hrs 
March 23, 2002
Disassembled tank and debured skin holes. Scuffed inside of tank were the
proseal will go. 2.0 hrs 
Back
to The
wing assembly page
May 5, 2002
Prepared tank parts for sealing. Installed the tank stiffeners, the Fuel cap,
and the fuel drain flange. 4.0 hrs May
26, 2002
Riveted the 2 center ribs in tank. 4.0 hrs May
27, 2002
Riveted 2 more ribs in tank. 4.0 hrs June
2, 2002
Riveted the last internal rib. 1.5 hrs 
June
15, 2002
Built Wing Stand.
Ordered 1/2" 8-32 Stainless Steel hex head screws from local hardware store
to install Tank access plate.
July 11, 2002
Assembled fuel pickup to access plate. Pro-sealed fuel capacity BNC connector to
inner rib and pro-sealed around access panel ring and platenuts. Installed
outmost rib in tank. 3.0 hrs. July
12, 2002
Installed Inboard Rib. 1.5 hrs July
27, 2002
Installed the last fuel capacative sender plate and install the rear baffle and
Z-brackets. You can see the bead of proseal thru the access panel hole. 5.5
hrs
Aug. 3, 2002
Installed the Round access panel and prosealed over some rivets that I still had
not been sealed. I applied EZ turn Lube (Fuel Lube) to the cork gasket and used
stainless steel allen head screws with a stainless steel flat washer, the gasket
sweezed out around the edges, but I wanted to make sure it was all tight, then I
prosealed all around the edges. You can also see the small piece of angle I
install to zip tie the fuel sender wire to as the plans suggest doing.1.5 hrs.
Aug.
6, 2002
Made a manometer and put 42" of water in it and mark that as the zero line.
I then attached it to the fuel tank vent. Capped the fuel supply fitting. Put
some EZ turn Lube on the fuel tank cap gasket and put it in place. I then blew
as hard as I could in the fuel drain but that did not get the water level high
enough, so I cranked up the air compressor and then drained it down to all most
nothing and attached my blower tip and put the rubber tip on the drain and
slowly added air till the water level had 42" difference between the two columns.
I think that is 1.5 PSI or close to it. In one hour the level had gone down
1" in three hours it had gone down 3" :-( I came back the next
morning and it had gone down a total of 11.5" I knew that the temperature
change had affected it, but not sure how much. I came back after work and knew
that if the tank had a leak the level would still be down but if it did not it
should be about were it was when I started since the temp. was about the same as
the day before. It was only 2.5" lower. That was what I was hope for, I let
the pressure off the tank and found 1" of the water had evaporated, so the
level was only 1.5" lower and I figured that to 1 degree of change the
water went down about 1/2". NO LEAKS! 2.5 hrs 
Oct 18, 2002
Started drilling LH tank skin holes to size 1.5 hrs
Oct
19, 2002
Finished drilling skin holes then countersunk all tank skin to rear baffle
holes. Drilled screw holes to size and disassembled tank. Started assembling Capacitive fuel probes.
6.0 hrs
Oct 20, 2002
Finished the fuel probes, worked on tanks attach angle - drilled the flop tube
fitting hole. 2.0 hrs Oct
21, 2002
Worked on fuel tank access hole and drilled screw holes thru inboard rib.
Drilled fuel filler ring to tank. 1.5 hrs Oct
22, 2002
Assembled fuel tank access cover ring to rib with nut plates and made anti hang-up
bracket. 2.0 hrs
Oct
24, 2002
Drilled drain fitting to tank skin. started scuffing areas in tank skin where
proseal will be used. 1.0 hrs
Oct 25, 2002
Deburred Tank skin, smoothed edges and dimple the top side of tank skin. 2.25 hrs
Nov 1, 2002
Dimple the Bottom side of tank skin. 1.75 hrs
Nov 2, 2002
The weather started getting cold and I was worried about prosealing in the cold
weather, I asked about it on the web and got a good idea back. Go to the Cold
Weather Proseal Tip on my Tips page to read about it.
Dimple the Ribs for the tank. Installed the tank stiffeners. 4.75 hrs Nov
3, 2002
Installed the Fuel cap flange and the drain flange. 1.0 hrs Nov
9, 2002
Installed 2 interior ribs. 2.0 hrs Nov
10, 2002
Installed 2 more ribs and dressed up the first two ribs. 3.0 hrs. 
Nov
16, 2002
Installed flap door on inboard rib next to flop tube. Made cover for center hole
but could not find instructions anywhere about installing it, I had seen it on
others web sites. 2.0 hrs. I
emailed Vans to find out if that hole is suppose to be covered and Gus replied
that yes it is. 
Nov 23, 2002
Finished work on above rib and made vent line. Installed outboard fuel prob.
(plate). Prepared tank for prosealing. 3.0 hrs Nov
24, 2002
Installed two more ribs. 4.0 hrs Nov
25, 2002
Finished up prosealing on all the ribs previously installed. Prepared Inboard
end rib for installing. 3.0 hrs
Dec 14, 2002
Installed outboard end rib and the flap door rib. Installed vent line and
inboard fuel prob. (plate). 4.5 hrs Dec
15, 2002
Installed inboard end rib and flop tube. 2.0 hrs
Dec 17, 2002
The proseal is curing very slowly, so I decided to take the tank home so that it
would be in a constant temp. environment. I set it in the utility room. The last
session of proseal is curing faster than the session before it. I should have
used just a bit more hardener in it. I let it sit for a few weeks. Might as well
get the flaps done, back
to the Wing assembly page.
May 31, 2003
After sitting at home thru the cold months, I ordered fresh proseal and install the rear baffle and
Z-brackets. 5.5 hrs
June1, 2003
Prosealed over the rivet ends. 1.5 hrs June
7, 2003
Sealed inspection cover closed, prepared and primed the bottom skins for the RH
wing 5.5 hrs June
13, 2003
Hooked up the manometer to find out if there are any leaks. 0.5 hrs 
June
15, 2003
Water level is still near the same level, it has gone down and back up the the
temp. changes. So it looks like there are no leaks :-) Both tanks are now
done! Now on to
finishing the wings!
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