Fuel Tanks

I am still debating whether to make aluminum or foam and fiberglass fuel tanks. I will keep you posted on my decision.

OK, I have decided on aluminum fuel tanks in the stub wings and for the header tank. Now, to locate a local supplier for some 5052-H32 aluminum. With the landing gear bracket out of the stubwing area there is more room for the fuel tanks.

I purchased a 2' x4' piece of high density polyethylene to use as a forming plug. I printed out the AS5048 airfoil with a 1/2" inside border. I glued the print out onto the HDPE and cut it out with the band saw. I sanded it to final shape with a 6" x 48" stationary belt sander. I sheared the 5052 aluminum to rough size, finished with aviation shears. I clamped the aluminum on to the HDPE form and used a body work hammer to form the lip to the airfoil shape. Be sure to make two rights and two lefts and mark them.

My stub wings are 26" long so I had two   5' x 24" sheets cut. These sheets will wrap around the perimeter of the end caps. The perimeter of the finished end caps were measured and marked on the sheets to bend them to the rough shape of the airfoil. Three 3" strips were bent into a "V" shape with flanges. This will be welded to the top inside of the tanks. The V's are to provide structural support for the wing walks.

Everything will be held in place with clecos and taken to the welder. The clecos will be removed after the tanks are tacked together. The heli-arc welder will weld the holes shut as he welds the tanks together. The filler, sump, vent, drain and fuel sender plates are drawn in CAD and then produced. They will be welded to the tanks at the same time.