'41 Deluxe Fuel Tank

[Peterroy]

Hi guys,

I have been tracking down a fuel leak. I'm not going to bore you with the details, but I am at a point where I will have to repair my main fuel tank, or replace it. The culprit is a pin-hole leak that appeared at the base of the tank when I scraped off a chip of paint with my fingernail.

Would you agree, if I can puncture the metal of my main fuel tank simply by removing a chip of paint with my fingernail, the condition of the metal is in question? My initial reaction is that the tank is rusted on the inside and other problems are in my future. That being the case, I don't think it wise to simply repair this pin-hole with the tank in place. I think it should be removed and repaired or replaced. (Skip and I will "scope" it tomorrow, but I'm fairly confident we will not see pristine metal.)

The area I live in has shops that have the talent to patch the bottom of the fuel tank. They could probably remove and replace the bottom half of it if I asked them to. With these skills at hand I have two choices; repair or replace the fuel tank. My initial reaction is to replace with new. QUESTION: does anyone have experience with the Taylorcraft fuel tank being sold by Wag Aero? Will it fit in a 1941 T-craft? If it will, that's what I'll do.

If the Wag Aero fuel tank won't fit, I guess I should ask, does anyone have a 1941 main fuel tank laying around that is in relatively good shape?

Looking forward to any and all responses. If you think there may be another way to go on this please advise.

Thanks,

Peter
1941 Deluxe N29780
1967 PA24-260B N9170P

[astjp2]

Re: '41 Deluxe Fuel Tank

Peter, just take it to a radiator shop and have them repair it, its probably a chunk of solder that pulled away or the tank is thin but the radiator shop can build up a lead layer that will hold up fine. You can take a flashlight and look inside the tank and it will tell you more than what is on the outside. The wag tank fits so if you want to get rid of yours, I will take it get it repaired and keep it as a spare for mine. Tim

[Peterroy]

Re: '41 Deluxe Fuel Tank

Thanks for the reply. Looking in the tank suggests it is not in that bad a shape. It would seem pulling the tank for repair is not worth the effort. I think I'm just going to solder it in place and see how it goes. Thanks again for your input.

Peter

[Hank Jarrett]

Re: '41 Deluxe Fuel Tank

Not sure that is such a good idea. I would NEVER solder on a tank in the plane. It takes just a TINY bit of fuel to vaporize and ignite while soldering to burn your plane to cinders (and maybe YOU!). I have seen a tank catch fire that was flushed several times with water and filled with CO2 before the torch got near it and it STILL flashed off!
The risk it pretty high and the effort to remove the tank and have it done professionally at a radiator shop would be worth the effort compared to the possible consequences. You would also be able to fully evaluate the tank from all sides and be sure there were no other little gremlins in it waiting to get you next.
If you DO take it to the radiator shop it would be a good idea to reinforce the area around the fuel outlet with a doubler. Seems like that area always causes trouble.

Hank

[astjp2]

Re: '41 Deluxe Fuel Tank

I second Hanks Opinion, pull the tank....its not an easy solder job, I weld and still sent my tank to the radiator shop. Just about everyone that I do the annual on goes out because of the same problem. Tim

[NC36061]

Re: '41 Deluxe Fuel Tank

Peter,

I have a different perspective from Tim and Hank. We are restoring a '41 Deluxe now, but replacing the original ternplate tanks with new aluminum ones from Wag-Aero. Your tank has to come out either way, but its 73 years old. Repairing it is cheaper I'm sure, and it might be "ok" but what if it starts leaking again? As long as you have to pull the tank, I'd seriously consider breaking down and getting a new one, you won't be worrying about the repair or a new leak starting and having to take it out again. Just my 2₵ as that's the route we decided to go.

Good luck,

Dave

[Hank Jarrett]

Re: '41 Deluxe Fuel Tank

Good point Dave. My position isn't taht repair is better than replace, just that repair in place is WAY too dangerous for me. Once it is out a good radiator shop will be able to see if the leak is minor or not. I would also pressure test it while out. Put a condom over the filler neck and put a LITTLE air in the tank. It is VERY EASY to damage the tank with air pressure. I use my mouth to blow into the fuel line, then closed the fuel valve to trap the air. Just blow till the condom fills up and let her sit for a few hours and see if it leaks out. Mine stayed inflated all night. Got a LOT of laughs from people going past my hangar!
I posted the photos of my test if anyone still has them. Can't find them in my files.

Hank

[3Dreaming]

Re: '41 Deluxe Fuel Tank

I had a Deluxe that was converted to a clip wing that I restored. The tank was clean, inspected , and tested before it went in the airplane. On the first fueling there was a pinhole leak squirting out fuel, and the tank had to come back out. When I restored my 41 BL I found a new old stock aluminum tank and installed it in place of the steel tank. I think If I was doing another I would do the aluminum tank. An added bonus is that it is a little lighter.

[astjp2]

Re: '41 Deluxe Fuel Tank

Well I will take the old one, I like the Tern plate better than the aluminum ones. That is a personal preference of mine because I now know how to repair the tern plate by taking it to the radiator shop near me, he builds up a nice layer that wont crack out. Tim

[skip]

Re: '41 Deluxe Fuel Tank

... I would also pressure test it while out. Put a condom over the filler neck and put a LITTLE air in the tank. It is VERY EASY to damage the tank with air pressure. I use my mouth to blow into the fuel line, then closed the fuel valve to trap the air. Just blow till the condom fills up and let her sit for a few hours and see if it leaks out. Mine stayed inflated all night. Got a LOT of laughs from people going past my hangar!
I posted the photos of my test if anyone still has them. Can't find them in my files.

Hank

OK Hank, Here's a picture. Not the main tank, but I did the test to my wing tanks during my wing rebuild last year. I used a schrader valve in a nylon plug on the fuel line output and blew up the condom. Overnight, the thing deflated a little and I was worried until I did the old Boyle's law thing on the hot hanger in the afternoon when the tank was filled vs the cool hanger in the early morning when I checked back. The cooler air shrinks a bit. No Leak!



It was difficult putting just a little vacum grease on the filler neck and then a good rubber band to make a good seal. I ended up ripping three condoms before I got the trick right for putting the thing on the filler neck. Someone looked in the trash at the failures and I mentioned that we had had a GREAT party the night before.

[Hank Jarrett]

Re: '41 Deluxe Fuel Tank

It takes practice to stretch one over a large diameter. Of course I didn't have any problems at all. ;-)

Hank

[Scott]

Re: '41 Deluxe Fuel Tank

if the pinhole is localized ie as you've said the tank looks in good shape otherwise, a simple and quick solution would be to do an external seal with PRC proseal or whatever they call it these days. two part fuel tank sealer that if applied correctly will last at least as long as the rest of the tank.

[astjp2]

Re: '41 Deluxe Fuel Tank

No it wont because of the fuel valve flexing the bottom of the tank, the lead solder will stiffen the bottom, spread the load out and keep it from cracking more. If you pro seal it, it will just continue to crack below the surface. You need the reinforcement as much as stopping the seep. Tim

[Peterroy]

Re: '41 Deluxe Fuel Tank

I just got back in town from a trip to Nevada and Utah, and am now catching up on the discussion about my fuel tank. Thanks for the input. Interestingly, about five minutes after landing in St. George, Utah last Friday, I got a call from Tim who, as mentioned above, strongly discouraged me from welding/soldering the fuel tank in place. I called the gentleman who was going to do the work for me and I guess he heeded Tim's suggestion. I just checked N29780 and the pinhole was not repaired.

The plane has been down now for three weeks. My problem is I am not a mechanic and I don't have a hangar. Any work I do is out on the ramp. While I probably have the skills necessary to remove the fuel tank, I'm not sure I can re-rig everything when I get it back in. Moreover, I am retiring in 65 days (9 hours, 3 minutes, and 8 seconds) and will be moving to southern Nevada. I would hate to have the airplane taken apart and left behind because something went awry. I will not have a hangar at my new airport, but if the plane gets stranded there, a least it would be at my new home.

I think this is what I will do. I'll apply a (quality) two-part epoxy sealant like the one sold by Permatex. Hopefully that will hold until I retire in 65 days (8 hours, 55 minutes, and 46 seconds). When I get the plane to its new home, I'll be in a better position to do the right thing which is to install a new tank. Tim, I'll send you the old one; or you can come down and pick it up. Again, thank you everyone for your input.

[astjp2]

Re: '41 Deluxe Fuel Tank

I can come down at the end of the month and help if that will make it better. The epoxy will contaminate the future solder repair. Tim