Canadian Flag Blowing In The Wind Ron Leclerc Zenith CH701 Construction Log


Zenair CH701 STOL Aircraft...
CH701 STOL

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701 Fuel System: 1 | 2 |    Next...
 

 
CH750 Wing - Fuel Tank Modification!

Since I will be going with the 750 Wing Rear Ribs... some mods to the Fuel tanks were necessary. The aft end of the Rear Rib is deeper then the 701 Rib and ends at the Rear Spar Channel where as the 701 Rib is full length, and goes past the Rear Spar Channel. The Spar channel of the 750 is one piece, while the 701 Spar Channel is 7 pieces(a much inferior design)...

When you start a project like this one... you have to do a lot of research and planning for it to go right! There is a lot of delicate measurements and bending to be done! You wonder how it will work out... will all of the parts fit together without any screwup with the measurements! Well I must say that this project turned out better then I would have expected to. I used my wood bending brake for all of the bends and it performed great. The Alumium Sheet used is specifically sheet for fuel tanks - 5052H-32 0.032". Only needed a 4 x 6 sheet for the project I purchased from ACS... wound up with a 4 x 8 sheet. I don't know how they measured this as they sell it in 4 x 6 sheets or 4 x 12 sheets only!

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August 15,2011:
CAD Drawing of new 701 Fuel Tank side wall... showing the locations of the ISS Fuel Tank Sender, 2 fuel VA-141 flange outlets and the fuel return VA-112 flange inlet... The side wall is 0.032 aluminum! The VA-112 and VA-141 riveted inlet and outlet flanges and are acquired from Van's Aircraft!

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August 15,2011:
CAD Drawing of new 750 Fuel Tank side wall(similar to 701)... showing the locations of the ISS Fuel Tank Sender, 2 fuel VA-141 flange outlets and the fuel return VA-112 flange inlet... The side wall is 0.032 aluminum! The VA-112 and VA-141 riveted inlet and outlet flanges and are acquired from Van's Aircraft!

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October 3, 2011
Modified CH701 Wing - Fuel Tank End Forming Blocks... will work for the CH750 tanks!

 
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December 17,2012
Here is the start of my modified fuel tanks - 4 x 6 sheet of 5052H-32 - 0.032" Aluminum specific for fuel tanks!

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December 17,2012
Tank end walls ready for cutting - 2 left and 2 right!

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December 18, 2012
Fuel Tank end wall blanks - 0.032 5032H aluminum!

 
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December 19,2012
Tank bottom skins - ready to be formed! Have to form the end walls first...

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December 19,2012
Tank bottom skins! Toughest part with this project is removing the 6mm thick plastic film on both the top and bottom of the sheet!

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December 20, 2012
Tank bottom skins - all bent up. My wooden bending brake worked great... got the bends right on!

 
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December 20, 2012
Fuel Tank end walls being formed...

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December 20, 2012
Tank End Walls all formed...

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December 20,2012
Right hand tank - next comes the Top Skin and the ISS Fuel tank sender with the VDO 1/8" steel mounting flange, inlet flange(return line) and sump drain flange(CAV-110), fuel outlet(front and rear) flanges(finger strainers) along with the vent line!!

 
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December 21,2012
Left hand tank - next comes the Top Skin and the ISS Fuel tank sender with the VDO 1/8" steel mounting flange, inlet flange(return line) and sump drain flange(CAV-110), fuel outlet(front and rear) flanges(finger strainers) along with the vent line!

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December 21, 2012
Fuel Tank tops - ready for drilling...

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December 22,2012
Left hand tank - with the top skin clecoed in place! All measurements were as per my design and went together better then expected!

 
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December 24,2012
Fuel Tank Venting... 1/4" size tubing and AN 4D fittings. The vent tubing will exit the rear of the tank and oriented into the direction of the air flow....
1-AN832-4D Bulkhead Union
1-AN924-4D Nut
1-AN960-716 Alum. Washer
2-AN818-4D Nuts
2-AN819-4D Sleeve
1/4" 3003 Soft tubing

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December 24, 2012
Inside of the tank showing the open end of the 1/4" vent line tubing. There is a flange bracket attached to the top cover to support the tube...

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December 24,2012
Rear of tank showing... orientation and direction of the 1/4" vent line tubing, into the air flow... Parts:

 
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December 24, 2012
Inside of tank showing the front and rear finger strainer fuel outlets mount wiith the VA-141 riveted flanges. Also the ISS fuel sender and the VDO 1/8" steel mounting flange

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December 24, 2012
Exterior left tank showing the finger strainers and ISS fuel sender and fuel return line VA-112 riveted flange ...

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December 24, 2012
Sump drain CAV-110 located in the bottom rear of the tank mounted in the VA-112 riveted flange...

 
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December 24, 2012
View of left tank ready for the interior baffle and then final finishing...

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December 24, 2012
View of right tank ready for the interior baffle and then final finishing...

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January 3, 2013
Fuel tank baffles - 1 left and 1 right 5052H32 aluminum

 
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January 3, 2013
Fuel tank baffle - installed in right tank. It sure add some strength to the tank!

 

 
Fuel Tank Drain Flanges and Finger Strainers!

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October 16, 2008
Sump drain flanges VA-112(1/8 NPT)... about $6 from Van's already drilled and CAV-110 sump drains from ACS... Aircraft Spruce

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October 16, 2008
These are the welded type of flanges available from ACS, but they must be trimmed and drilled... now they can both be had from Van's already drilled... the VA-112(1/8 NPT) and VA-141(3/8 NPT). The VA-141 is quite expensive about $20... Aircraft Spruce

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October 16, 2008
These are the welded type of flanges trimmed, drilled and the finger strainer is available from ACS... about $7. I had this flange already before I found them at Van's... so I trimmed and drilled and... then cut the flange level with the bottom of the tank, the trimming and drilling is a lot of work...so next time will buy from Van's... Aircraft Spruce

 
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October 16, 2008
The 3 flanges on the right are welding flanges from ACS - Aircraft Spruce that must be formed and rivet holes drilled. The one on the right is before forming and rivet hole drilled. I decided to use Van's Rivet Type Flanges already formed and with the rivet holes...

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August 15, 2011:
Change of plan...
Found these - 3/8 NPT Rivet Type Flanges(VA-141) at Van's... 2 outlet(finger strainers) locations for each tank. One for the front of the tank and one for the rear(original design location). The rivet type of flanges(VA-141) are from Van's Aircraft, with formed flange and rivet holes already drilled... $20 each.

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August 15, 2011:
4 - 3/8" NPT Sump Finger Screens & Rivet Flanges(VA-141)... 2 for each tank. One for the front of the tank and one for the rear(original design location).

 
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August 15,2011:
4 - 1/8" NPT Rivet Flanges(VA-112) from Van's Aircraft - 1 for the CAV-110 Sump Drains on each tank and 1 for the Fuel Return line on each tank...

 

 
VDO Fuel Tank Sending Unit & Gauge... Scrapped these and switched to ISS engine Gauges made by Stewart Warner!

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November 29, 2008
VDO Fuel Sending Unit: #221-012... 10ohm to 70ohm... The arm is bent as per Zenith instructions, but located in the tank to match the higher profile of the modified tank end...

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November 29, 2008
Fuel Sender mounting ring blank - 6061 T6 1/8" aluminum, ready to have 40mm hole cut...

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November 29, 2008
Fuel Sender mounting ring blank... with the 40mm hole, ready to drill the 5/32" holes and then tap for 10-32, 1/2" brass machine screws...

 
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November 29, 2008
Finished mounting ring, with 10-32 tapped 5/32" holes...
This ring is used instead of the VDO #226-451 sender mounting ring... priced out at $23/per plus $20 shipping so there you have it...

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February 7, 2009
VDO Fuel Gauge - 301 020... 10ohm to 70ohm. This is the fuel gauge thats needed for the VDO Fuel Sending Unit: #221-012. Purchased from Summit Racing Equipment...

 

 
New ISS Fuel Gauges and Senders - From Van's and ACS
I purchased the ISS Gauges from Aircraft Spruce for $40(Van's cost $36)... and the Fuel tank senders from Van's(ACS - $32.50/$35) for $27! The Gauges were also cheaper at Van's, but they were calibrated in gallons for their tanks... hence I bought form ACS!

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August 15,2011:
ISS Fuel Gauges and Senders. These are 2.25" aircraft gauges instead of the junk 2" VDO Gauges which are automotive! Much better quality by Stewart Warner. Available from both Van's Aircraft and Aircraft Spruce. If you order from Van's the Gauges will be branded with Van's name on them.

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August 15,2011:
ISS Fuel Tank sender by Stewart Werner. Used by Van's Aircraft... available from both Van's Aircraft(cheaper) and Aircraft Spruce.. The wire arms are available in 3 lengths, these are the 6" - 12" long arm.

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August 15,2011:
ISS Fuel Tank senders must be bent in a left and right configuration. Note the short 20mm bend of the short end...

 
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August 15,2011:
ISS Fuel Tank Senders bent into shape ready to be installed in the tank... Note left and right installation in tank!

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August 15,2011:
ISS Fuel Tank senders side view... Note that the flange mounting holes are the same as the VDO senders and the gaskets are also the same... but the flange is steel and 1/8" thick!

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August 15,2011:
CAD Drawing of bending procedure used. I made up this drawing as the procedures I received from Van's were for their aircraft tanks. I'm using a different tank profile... but is not too hard to do. Just be aware that the sender is installed up 10mm from the middle of the tank(center position)...

 
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August 15,2011:
Note the installation of the ISS Fuel Sender in the Van's tank drawing.

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August 15,2011:
Installation of the ISS Fuel Tank sender in the tank...

 

 
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