Steve White Fuel Tank Repair - Revision history

WikiSysop at 16:33, 5 April 2009

2009-04-05T16:33:41Z

← Older revision		Revision as of 16:33, 5 April 2009
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	[[Image:plane.jpg]]		[[Image:plane.jpg\|thumb\|300 px\|Steve White's Traveler]]

	On Jan3, 2006 I bought this 1974, 2-owner, AA-5 with 1441TT and 80hrs SMOH with HC. In the next 9 months my wife says that I tried to see how much money I could spend on the airplane. She was wrong, but not by much. We put on new alt, starter, vac pump, el fuel pump, all new hoses, tires, all DMA mods, RR cap, all antennas buried, Mitchell gauges, most instruments re-built, new transponder, new Sens prop - balanced also, paint, new interior, lots more, AND the right tank re-sealed. I was not involved in the re-sealing of the tank. Under the watchful oversight of my A&P - keeping everything legal, I replaced brakes, the Belleville washers, bearings, did new baffling, replaced the control bearings with the SS mod, re-rigged the control surfaces, replaced points and condenser/electronically timed the internal timing of the mags, re-installed the same, and on and on. I'm envious of [[User:~~Bob_Steward~~\|~~Bob Steward~~]] ~~and others who do this for a living. All this is to say, I really enjoy working on my plane. That is maybe I still do after twice into my~~ fuel ~~tank~~.		[[User:Steve_White\|Steve White]] contributed his story of the repair of leaking fuel tanks in his Traveler.

	~~My A&P~~ and I ~~tackled it~~ the ~~first time~~, by ~~the book~~. We ~~did just as the 2 other~~ fuel ~~tank repair accountings: scraped forever and got everything super clean. This is~~ the ~~same~~ tank ~~that had been~~ re-sealed ~~just 2 yrs ago~~. ~~None of the old material had been removed and the material we removed that~~ was ~~over~~ the ~~original sealer was~~ the ~~"low adhesive" material designated for usage on the access panels~~. ~~There was a lot~~ of ~~gravel in this sealer. This sealing was done by a mechanic who no longer works at~~ my ~~AI's place. The mechanic took out~~ the ~~fuel sender unit. We worked together at night and then I worked alone for about a week at night and then he checked everything with flashlight and mirrors~~, ~~we cleaned~~ the ~~tank and resealed~~ with the 3207B(thick) sealer. Messy!! We checked the next night and saw places that seemed to need attention and resealed. I then checked the next night and even yet there was a place needing attention and resealed. He checked again and gave it his blessing. He let me re-~~install~~ the ~~fuel sender unit(new gasket~~, ~~of course). I want to meet who ever designed those stupid grills that go on~~ the ~~outside~~ of the ~~bolts that hold~~ the ~~sender unit in. This job was never meant to be done. We filled the tank with 5 gal~~ and ~~left overnight~~ and ~~no leak, 5 more gal and still no leak~~. ~~Then filled it and left overnight~~ and a ~~slight seep~~. I ~~just couldn't believe it! I wasn't ready to go back in~~. I ~~flew it for 3 months~~.		On Jan 3, 2006, I bought this 1974, 2-owner, AA-5 with 1441TT and 80hrs SMOH with HC. In the next nine months my wife says that I tried to see how much money I could spend on the airplane. She was wrong, but not by much. We put on new alt, starter, vac pump, electric fuel pump, all new hoses, tires, all DMA mods, RR cap, all antennas buried, Mitchell gauges, most instruments re-built, new transponder, new Sens prop - balanced also, paint, new interior, lots more, AND the right tank re-sealed. I was not involved in the re-sealing of the tank. Under the watchful oversight of my A&P - keeping everything legal, I replaced brakes, the Belleville washers, bearings, did new baffling, replaced the control bearings with the SS mod, re-rigged the control surfaces, replaced points and condenser/electronically timed the internal timing of the mags, re-installed the same, and on and on. I'm envious of [[User:Bob_Steward\|Bob Steward]] and others who do this for a living. All this is to say, I really enjoy working on my plane. That is maybe I still do after twice into my fuel tank.

	Armed with more information from [[User:Bob_Steward\|Bob S.]], Garner, and Jeff Simon, the re-seal began. New equipment was used. A Milwaukee remote viewer, a web-cam/laptop, a dental spatula, and a hair drier greatly helped this process. They are pictured below:		My A&P and I tackled it the first time, by the book. We did just as the two other fuel tank repair accounts: scraped forever and got everything super clean. This is the same tank that had been re-sealed just two years ago. None of the old material had been removed and the material we removed that was over the original sealer was the "low adhesive" material designated for usage on the access panels. There was a lot of gravel in this sealer. This sealing was done by a mechanic who no longer works at my IA's place. The mechanic took out the fuel sender unit. We worked together at night and then I worked alone for about a week at night and then he checked everything with flashlight and mirrors, we cleaned the tank and resealed with the 3207B (thick) sealer. Messy!! We checked the next night and saw places that seemed to need attention and resealed. I then checked the next night and even yet there was a place needing attention and resealed. He checked again and gave it his blessing. He let me re-install the fuel sender unit(new gasket, of course). I want to meet who ever designed those stupid grills that go on the outside of the bolts that hold the sender unit in. This job was never meant to be done. We filled the tank with five gallons and left overnight and no leak, five more gallons and still no leak. Then we filled it and left it overnight, and noticed a slight seeping. I just couldn't believe it! I wasn't ready to go back in. I flew it for three months.

			Armed with more information from [[User:Bob_Steward\|Bob S.]], Garner Rice, and Jeff Simon, the re-seal began. New equipment was used. A Milwaukee remote viewer, a web-cam/laptop, a dental spatula, and a hair drier greatly helped this process. They are pictured below:

	[[Image:02-28-09_1657.jpg]]		[[Image:02-28-09_1657.jpg]]
Line 11:		Line 13:
	[[Image:02-28-09_1610.jpg]]		[[Image:02-28-09_1610.jpg]]

	~~1st~~, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.		First, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.

	[[Image:02-28-09_1623.jpg]]		[[Image:02-28-09_1623.jpg]]

	Then I tried the dental spatula: no avail. I was afraid I'd tear up my panel. Drove home and got a ~~hairdrier~~. I gently warmed the entire access panel to where it was warm but not hot and kept it warm for about 5 minutes. Then, I was able to ease the dental spatula under the panel. It works best at the beginning of the curvature of the panel. THIS IS A GOOD TECHNIQUE, IMO.		Then I tried the dental spatula to no avail. I was afraid I'd tear up my panel. Drove home and got a hair drier. I gently warmed the entire access panel to where it was warm but not hot and kept it warm for about five minutes. Then, I was able to ease the dental spatula under the panel. It works best at the beginning of the curvature of the panel. THIS IS A GOOD TECHNIQUE, IMO.

	[IMG]http://img.photobucket.com/albums/v503/sewdds/03-01-09_1425.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/03-01-09_1425.jpg[/IMG]
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	[IMG]http://img.photobucket.com/albums/v503/sewdds/02-28-09_1611.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/02-28-09_1611.jpg[/IMG]

	This was repeated 3 times - all panels off. The fuel sender unit was left in this time.		This was repeated three times, all panels off. The fuel sender unit was left in this time.

	Now, I very carefully checked all bond seams by tapping with a ~~1/2~~ dollar. I checked under and over the wing. This takes time, or at least I took a lot of time. My plane has purple sealer. No bond seam failure seemed to be present.		Now, I very carefully checked all bond seams by tapping with a half-dollar coin. I checked under and over the wing. This takes time, or at least I took a lot of time. My plane has purple sealer. No bond seam failure seemed to be present.

	The drop light:		The drop light:
	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80944.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80944.jpg[/IMG]

	Now armed with the web-cam and a 13 watt energy saver bulb(produces very little heat) in a drop light, the inspection began. Was my A&P blind that night?!! Was I?!! No wonder it leaked. It all looked so good with the flashlight and mirror and so terrible with the drop light and web-cam and to a lesser degree of detail, the Milwaukee remote viewer. Look at these pictures of our "terrible" job.		Now armed with the web-cam and a 13-watt energy saver bulb (produces very little heat) in a drop light, the inspection began. Was my A&P blind that night?! Was I?! No wonder it leaked. It all looked so good with the flashlight and mirror and so terrible with the drop light and web-cam and to a lesser degree of detail, the Milwaukee remote viewer. Look at these pictures of our "terrible" job.

	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-77784.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-77784.jpg[/IMG]
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	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]

	Though this is a picture taken a couple of years ago and before the "N"# change ~~AND~~(I'm happy to say) a few extra pounds ago, this picture depicts how a pilot feels and a plane looks after the leak is fixed.		Though this is a picture taken a couple of years ago and before the "N"# change and (I'm happy to say) a few extra pounds ago, this picture depicts how a pilot feels and a plane looks after the leak is fixed.
	[IMG]http://img.photobucket.com/albums/v503/sewdds/untitled4.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/untitled4.jpg[/IMG]


	'''Summary of things I learned that haven't been mentioned previously:'''		'''Summary of things I learned that haven't been mentioned previously:'''

	* Hair drier helps immensely with removing access panels		* Hair drier helps immensely with removing access panels.
	* A web-cam/laptop is all the remote viewing I need		* A web-cam/laptop is all the remote viewing I need.
	* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowledgeable will correct this assumption of mine		* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowledgeable will correct this assumption of mine.
	* You can't check too much		* You can't check too much.
	* Check to see if any de-bonding has occurred before any sealing begins: you may need both SK-125A procedures and sealing		* Check to see if any de-bonding has occurred before any sealing begins: you may need both SK-125A procedures and sealing.
	* A 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A"		* A 13-watt energy saving bulb provides plenty of light and very low heat (to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A."
	* Paint thinner helps clean off the low adhesive flash		* Paint thinner helps clean off the low adhesive flash.
	* I actually kind of enjoyed this, but not enough to do your plane.		* I actually kind of enjoyed this, but not enough to do your plane.

Steve White at 01:39, 20 March 2009

2009-03-20T01:39:11Z

← Older revision		Revision as of 01:39, 20 March 2009
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	* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowledgeable will correct this assumption of mine		* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowledgeable will correct this assumption of mine
	* You can't check too much		* You can't check too much
	* Check to see if any de-bonding has occurred before ~~and~~ sealing begins: you may need both SK-125A procedures and sealing		* Check to see if any de-bonding has occurred before any sealing begins: you may need both SK-125A procedures and sealing
	* A 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A"		* A 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A"
	* Paint thinner helps clean off the low adhesive flash		* Paint thinner helps clean off the low adhesive flash
	* I actually kind of enjoyed this, but not enough to do your plane.		* I actually kind of enjoyed this, but not enough to do your plane.

Steve White at 11:46, 19 March 2009

2009-03-19T11:46:45Z

← Older revision		Revision as of 11:46, 19 March 2009
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	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-79615.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-79615.jpg[/IMG]
	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]

			Though this is a picture taken a couple of years ago and before the "N"# change AND(I'm happy to say) a few extra pounds ago, this picture depicts how a pilot feels and a plane looks after the leak is fixed.
			[IMG]http://img.photobucket.com/albums/v503/sewdds/untitled4.jpg[/IMG]


	'''Summary of things I learned that haven't been mentioned previously:'''		'''Summary of things I learned that haven't been mentioned previously:'''

Bob Steward: spelling correction

2009-03-18T04:59:19Z

spelling correction

← Older revision		Revision as of 04:59, 18 March 2009
Line 82:		Line 82:
	* Hair drier helps immensely with removing access panels		* Hair drier helps immensely with removing access panels
	* A web-cam/laptop is all the remote viewing I need		* A web-cam/laptop is all the remote viewing I need
	* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more ~~knowlable~~ will correct this assumption of mine		* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowledgeable will correct this assumption of mine
	* You can't check too much		* You can't check too much
	* Check to see if any de-bonding has occurred before and sealing begins: you may need both SK-125A procedures and sealing		* Check to see if any de-bonding has occurred before and sealing begins: you may need both SK-125A procedures and sealing

Bob Steward: Bolded text for summary header

2009-03-18T04:57:44Z

Bolded text for summary header

← Older revision		Revision as of 04:57, 18 March 2009
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	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]

	Summary of things I learned that haven't been mentioned previously:		'''Summary of things I learned that haven't been mentioned previously:'''

	* Hair drier helps immensely with removing access panels		* Hair drier helps immensely with removing access panels

Bob Steward: Created bullet list for items at end, spelling correction

2009-03-18T04:55:58Z

Created bullet list for items at end, spelling correction

← Older revision		Revision as of 04:55, 18 March 2009
Line 78:		Line 78:
	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]

	Summary of things I learned that haven't been mentioned previously: ~~1) hair~~ drier helps immensely with removing access panels~~, 2)~~ web-cam/laptop is all the remote viewing I need~~, 3) type~~ "A" is easier for me to use 1st and third while type"B" would be used in-between. There may be good reasons to not do this, and maybe someone more knowlable will correct this assumption of mine~~, 4) you~~ can't check too much~~, 5) check~~ to see if any de-bonding has occurred before and sealing begins: you ~~man~~ need both SK-125A procedures and sealing~~, 6) a~~ 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A"~~, 7) paint~~ thinner helps clean off the low adhesive flash~~, 8)~~ I actually kind of enjoyed this, but not enough to do your plane.		Summary of things I learned that haven't been mentioned previously:

			* Hair drier helps immensely with removing access panels
			* A web-cam/laptop is all the remote viewing I need
			* Type "A" is easier for me to use 1st and third while type "B" would be used in-between.There may be good reasons to not do this, and maybe someone more knowlable will correct this assumption of mine
			* You can't check too much
			* Check to see if any de-bonding has occurred before and sealing begins: you may need both SK-125A procedures and sealing
			* A 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A"
			* Paint thinner helps clean off the low adhesive flash
			* I actually kind of enjoyed this, but not enough to do your plane.

Bob Steward: Moved photo from Photobucket to Bondline

2009-03-18T04:47:58Z

Moved photo from Photobucket to Bondline

← Older revision		Revision as of 04:47, 18 March 2009
Line 13:		Line 13:
	1st, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.		1st, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.

	[~~IMG]http~~:~~//img.photobucket.com/albums/v503/sewdds/~~02-28-09_1623.jpg~~[/IMG~~]		[[Image:02-28-09_1623.jpg]]

	Then I tried the dental spatula: no avail. I was afraid I'd tear up my panel. Drove home and got a hairdrier. I gently warmed the entire access panel to where it was warm but not hot and kept it warm for about 5 minutes. Then, I was able to ease the dental spatula under the panel. It works best at the beginning of the curvature of the panel. THIS IS A GOOD TECHNIQUE, IMO.		Then I tried the dental spatula: no avail. I was afraid I'd tear up my panel. Drove home and got a hairdrier. I gently warmed the entire access panel to where it was warm but not hot and kept it warm for about 5 minutes. Then, I was able to ease the dental spatula under the panel. It works best at the beginning of the curvature of the panel. THIS IS A GOOD TECHNIQUE, IMO.

Bob Steward: Moved photo from Photobucket to Bondline

2009-03-18T04:39:03Z

Moved photo from Photobucket to Bondline

← Older revision		Revision as of 04:39, 18 March 2009
Line 7:		Line 7:
	Armed with more information from [[User:Bob_Steward\|Bob S.]], Garner, and Jeff Simon, the re-seal began. New equipment was used. A Milwaukee remote viewer, a web-cam/laptop, a dental spatula, and a hair drier greatly helped this process. They are pictured below:		Armed with more information from [[User:Bob_Steward\|Bob S.]], Garner, and Jeff Simon, the re-seal began. New equipment was used. A Milwaukee remote viewer, a web-cam/laptop, a dental spatula, and a hair drier greatly helped this process. They are pictured below:

	[~~IMG]http~~:~~//img.photobucket.com/albums/v503/sewdds/~~02-28-09_1657.jpg~~[/IMG~~]		[[Image:02-28-09_1657.jpg]]
	[~~IMG]http~~:~~//img.photobucket.com/albums/v503/sewdds/~~03-01-09_1445.jpg~~[/IMG~~]		[[Image:03-01-09_1445.jpg]]
	[~~IMG]http~~:~~//img.photobucket.com/albums/v503/sewdds/~~02-28-09_1610.jpg~~[/IMG~~]		[[Image:02-28-09_1610.jpg]]

	1st, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.		1st, the access panels just wouldn't budge. I used the small pointed instrument to remove the external adhesive but that didn't seem to help.

Bob Steward: Moved photo from Photobucket to Bondline

2009-03-18T04:32:27Z

Moved photo from Photobucket to Bondline

← Older revision		Revision as of 04:32, 18 March 2009
Line 1:		Line 1:
	[~~IMG]http~~:~~//img.photobucket.com/albums/v503/sewdds/~~plane.jpg~~[/IMG~~]		[[Image:plane.jpg]]

	On Jan3, 2006 I bought this 1974, 2-owner, AA-5 with 1441TT and 80hrs SMOH with HC. In the next 9 months my wife says that I tried to see how much money I could spend on the airplane. She was wrong, but not by much. We put on new alt, starter, vac pump, el fuel pump, all new hoses, tires, all DMA mods, RR cap, all antennas buried, Mitchell gauges, most instruments re-built, new transponder, new Sens prop - balanced also, paint, new interior, lots more, AND the right tank re-sealed. I was not involved in the re-sealing of the tank. Under the watchful oversight of my A&P - keeping everything legal, I replaced brakes, the Belleville washers, bearings, did new baffling, replaced the control bearings with the SS mod, re-rigged the control surfaces, replaced points and condenser/electronically timed the internal timing of the mags, re-installed the same, and on and on. I'm envious of [[User:Bob_Steward\|Bob Steward]] and others who do this for a living. All this is to say, I really enjoy working on my plane. That is maybe I still do after twice into my fuel tank.		On Jan3, 2006 I bought this 1974, 2-owner, AA-5 with 1441TT and 80hrs SMOH with HC. In the next 9 months my wife says that I tried to see how much money I could spend on the airplane. She was wrong, but not by much. We put on new alt, starter, vac pump, el fuel pump, all new hoses, tires, all DMA mods, RR cap, all antennas buried, Mitchell gauges, most instruments re-built, new transponder, new Sens prop - balanced also, paint, new interior, lots more, AND the right tank re-sealed. I was not involved in the re-sealing of the tank. Under the watchful oversight of my A&P - keeping everything legal, I replaced brakes, the Belleville washers, bearings, did new baffling, replaced the control bearings with the SS mod, re-rigged the control surfaces, replaced points and condenser/electronically timed the internal timing of the mags, re-installed the same, and on and on. I'm envious of [[User:Bob_Steward\|Bob Steward]] and others who do this for a living. All this is to say, I really enjoy working on my plane. That is maybe I still do after twice into my fuel tank.

Steve White at 01:16, 18 March 2009

2009-03-18T01:16:57Z

← Older revision		Revision as of 01:16, 18 March 2009
Line 78:		Line 78:
	[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]		[IMG]http://img.photobucket.com/albums/v503/sewdds/2009-04-01-80799.jpg[/IMG]

	Summary of things I learned that haven't been mentioned previously: 1) hair drier helps immensely with removing access panels, 2) web-cam/laptop is all the remote viewing I need, 3) type "A" is easier for me to use 1st and third while type"B" would be used in-between. There may be good reasons to not do this, and maybe someone more knowlable will correct this assumption of mine, 4) you can't check too much, 5) check to see if any de-bonding has occurred before and sealing begins: you man need both SK-~~121~~ procedures and sealing, 6) a 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A", 7) paint thinner helps clean off the low adhesive flash, 8) I actually kind of enjoyed this, but not enough to do your plane.		Summary of things I learned that haven't been mentioned previously: 1) hair drier helps immensely with removing access panels, 2) web-cam/laptop is all the remote viewing I need, 3) type "A" is easier for me to use 1st and third while type"B" would be used in-between. There may be good reasons to not do this, and maybe someone more knowlable will correct this assumption of mine, 4) you can't check too much, 5) check to see if any de-bonding has occurred before and sealing begins: you man need both SK-125A procedures and sealing, 6) a 13 watt energy saving bulb provides plenty of light and very low heat(to help protect the bonding), syringes are helpful for placement of both "A" and "B" viscosities. A paint brush helps with the "A", 7) paint thinner helps clean off the low adhesive flash, 8) I actually kind of enjoyed this, but not enough to do your plane.