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Fuel Filler Neck Woes

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Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Sun Apr 01, 2007 5:50 pm Post subject: Fuel Filler Neck Woes

I'm posting this in the hope that others may be spared the problem that I faced with my fuel tank filler.  About two months ago I installed capacitance type fuel level sensors in my 15 gallon ZAC made tanks.  Deciding it would be a good idea to test for leaks I put about 5 gallons of fuel in each one, screwed the filler neck in by hand, installed the cap and set them aside for a couple of weeks.   There were no leaks and after I drained the fuel out I went to remove the filler neck.   The left tank came apart ok but the neck in the right one moved about half a turn and stuck.   I and an A & P mechanic friend tried everything we could think of but in the end had to carefully cut the filler neck out.  It was almost like the threads had welded together, even though I had used oil on them before installing.  For what it was worth, I had noticed a couple of spots that turned a little harder when I screwed it in.



I contacted ZAC and they informed me that they would put me on the list to borrow the "big tap" to clean the tank flange's threads out.   It was a few weeks before it was my turn but when it came this week I used it successfully to clean up the threads in both tanks.  When finished, the new neck  (almost a $70 part) screwed in and out very easily.



Today I installed it using a thread sealant and it when on very nicely.  I would recommend to anyone that if your filler does not turn in easily that you may want to clean up the threads before trying to install.  I've heard of other builders that have had similar problems of freezing threads and it can be costly in time and money to repair.



Tim Juhl

Starting Left Wing - Right finished (finally)

Jabiru 3300A

Before&After.jpg

Description:

Filler neck after removal - new filler successfully installed!

Filesize:

46.79 KB

Viewed:

458 Time(s)

_________________
______________
CFII
Champ L16A flying
Zodiac XL - Jabiru 3300A
Almost done! It'll fly in spring!

n787xl(at)aol.com
Guest

Posted: Sun Apr 01, 2007 6:10 pm Post subject: Fuel Filler Neck Woes

Tim

 

 I had a similiar problem and solved it by making a tool out of delrin that fit the filler neck and was large enough so I could apply the required torque to remove the filler neck.

 

 regards

  James S

 

   

  

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Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Mon Apr 02, 2007 7:04 am Post subject: Re: Fuel Filler Neck Woes

James,



I carved a piece of 2 x 4 to conform to the inner shape of the filler neck so that I could put some leverage on it.  The wood splintered before the neck moved.  I stopped there because I was afraid of damaging the threads in the welded flange which would have really been a pain.  



The threads are small and fairly soft and I guess the fact that there is a waiting list for the tap indicates it is not an uncommon problem.



I'm glad you solved your problem OK.



Tim

_________________
______________
CFII
Champ L16A flying
Zodiac XL - Jabiru 3300A
Almost done! It'll fly in spring!

n787xl(at)aol.com
Guest

Posted: Mon Apr 02, 2007 8:33 am Post subject: Fuel Filler Neck Woes

Tim

 

 I was one of the builders that used the ZAC tap and countersink kit.  I got the job done but it was not easy.

 

 I used delrin (a machinable plastic) for extracting the filler neck.  It will  never splinter, however it is expensive, it was a machine shop discard so it didn't cost me anything.  I think if you made it of aluminum or steel it would work if you made it under size and wraped it with many turns of duct tape.

 

 I don't think you could damage the threads if slowly applied the torque.

 

 Regards

 

 James S.

 

 built 200hp RV6a, flying it.

 60% 601XL since 11/06

 

   

  

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ashontz

Joined: 27 Dec 2006
Posts: 723

Posted: Mon Apr 02, 2007 8:46 am Post subject: Re: Fuel Filler Neck Woes

Where did these filler necks come from?



If you can't get the tap, I suppose using a dremel with a wire brush may help clean the thread up. I'd try them before instaling in in the plane.



do not archive

Trainnut01(at)aol.com
Guest

Posted: Mon Apr 02, 2007 9:30 am Post subject: Fuel Filler Neck Woes

I made my "stuck neck removal tool" from steel with a two foot handle. I  wrapped several layers of duct tape around the point where it engaged the  fitting. The fitting then came out easily but it did make a couple of small  indentions inside the neck. The indentions  were easy to clean up using a  pattern file. Then I wore out two Dremel wire wheels cleaning the threads. After  that they screwed back in by hand using a piece of 1/4 inch plywood to turn  them.

 CJ

 THE WINGS ARE DONE!

  

 do not archive



See what's free at AOL.com. 

  [quote][b]

Michael Valentine

Joined: 09 Jan 2006
Posts: 108

Posted: Mon Apr 02, 2007 9:46 am Post subject: Fuel Filler Neck Woes

I had trouble getting one out before I had them installed in the wing.  I put some 3-in-1 oil around the threads and let it seep in.  Still took some real doing at first, but then it got going and came right out.  (Probably not helpful if it is already installed because you wouldn't have access to the threads, but I'm not sure what stage the OP is at!) 



Michael in NH



On 4/2/07, Trainnut01(at)aol.com (Trainnut01(at)aol.com) <Trainnut01(at)aol.com (Trainnut01(at)aol.com) > wrote:[quote]     I made my "stuck neck removal tool" from steel with a two foot handle. I  wrapped several layers of duct tape around the point where it engaged the  fitting. The fitting then came out easily but it did make a couple of small  indentions inside the neck. The indentions  were easy to clean up using a  pattern file. Then I wore out two Dremel wire wheels cleaning the threads. After  that they screwed back in by hand using a piece of 1/4 inch plywood to turn  them.

 CJ

 THE WINGS ARE DONE!

  

 do not archive



 See what's free at  AOL.com. 

  [quote][b]  http://www.matronics.com/Navigator?Zenith-List http://forums.matronics.com  [quote][b]

ccwacker(at)HOTMAIL.COM
Guest

Posted: Mon Apr 02, 2007 10:36 am Post subject: Fuel Filler Neck Woes

Tim,



I had the same problem but called Roger before it was to late. I did have to 

buy a new cap because i roughed it up pretty good removing it. The tap did 

the job, I can now remove the caps with my hand using a towel to prevent 

slippage.



Chuck Wacker

N601CW, Quick Build

 	  Quote: 	
		  From: "Tim Juhl" <juhl(at)avci.net>

Reply-To: zenith-list(at)matronics.com

To: zenith-list(at)matronics.com

Subject: Re: Fuel Filler Neck Woes

Date: Mon,  2 Apr 2007 08:04:44 -0700






James,



I carved a piece of 2 x 4 to conform to the inner shape of the filler neck 

so that I could put some leverage on it.  The wood splintered before the 

neck moved.  I stopped there because I was afraid of damaging the threads 

in the welded flange which would have really been a pain.



The threads are small and fairly soft and I guess the fact that there is a 

waiting list for the tap indicates it is not an uncommon problem.



I'm glad you solved your problem OK.



Tim



--------

DO NOT ARCHIVE

______________

CFII

Champ L16A flying

Zodiac XL - Jabiru 3300A

Working on wings





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dredmoody(at)cox.net
Guest

Posted: Mon Apr 02, 2007 10:44 am Post subject: Fuel Filler Neck Woes

I have enjoyed reading this thread. When I did mine, the system was still not well though out. The filler necks could not screw down deep enough into the female fittings on the tanks to make contact with the LE skins. That was because they had a brain jam in the design/fabrication dept. and they were welding the female fittings on the outside (the top) of the tank skin. I had to bevel the female fittings by myself (freehand) then clean the threads with a wire brush as mentioned elsewhere in this thread. 



After working through the problem, I called the factory to suggest to the brothers Heintz that they get the tanks made with the female fitting welded inside the tank (under the top skin of the tank) so that the filler neck woudl have more room to screw down before bottoming out. I was told that they had just begun doing  that....... I was just a bit too early to get that update. No way to avoid that sort of cosmic coincidence...... manure occurs.



Dred

chris Sinfield

Joined: 28 Nov 2006
Posts: 270
Location: Sydney Australia

Posted: Mon Apr 02, 2007 3:00 pm Post subject: Re: Fuel Filler Neck O ring

Any one know where to get replacement O rings for the Zenith Locking fuel caps?? Who makes the actual plastic cap?

Chris..

paulrod36(at)msn.com
Guest

Posted: Mon Apr 02, 2007 3:25 pm Post subject: Fuel Filler Neck Woes

<?xml:namespace prefix="v" /><?xml:namespace prefix="o" /><![endif]-->  One more suggestion. If it's tight or grabby going in, you might consider  smearing some valve grinding compound on it, and "lapping" the threads just  enough for a smooth thread. Wipe and rinse very thoroughly (don't want to ingest  carbide into the engine) and it should work smoothly. I've done this on  problematic bolt threads, and sliding pieces, and it worked well.

  

 Paul Rodriguez

 601XL/Corvair

 *&^%$#(at)*&^%$#CANOPY!!!

 [quote]   ---

p.mulwitz(at)worldnet.att
Guest

Posted: Mon Apr 02, 2007 3:45 pm Post subject: Fuel Filler Neck Woes

Hi Chris,



You should be able to get just about any O-ring at your local hardware store.



I saw filler caps exactly like the one ZAC shipped me in the Aircraft 

Spruce catalog.



Paul

XL fuselage

do not archive



At 03:00 PM 4/2/2007, you wrote:

 	  Quote: 	
		  

<chris_sinfield(at)yahoo.com.au>



Any one know where to get replacement O rings for the Zenith Locking 

fuel caps?? Who makes the actual plastic cap?

Chris..




	


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dredmoody(at)cox.net
Guest

Posted: Mon Apr 02, 2007 4:46 pm Post subject: Fuel Filler Neck Woes

Oh my...... I seem to have started  something...

 Dred

 Do Not Archive

 Do Not Forget Your Prozac when working on the #!$&%(at)!!*#% ([email]#!$&%(at)!!*#%[/email])!!! canopy

 [quote]   ---

sperry50(at)comcast.net
Guest

Posted: Mon Apr 02, 2007 6:06 pm Post subject: Fuel Filler Neck Woes

I had a similar problem. It appears that when they welded the tanks for the

quick-build kit no one thought to check them and see if the neck would still

screw in. Unfortunately, mine were VERY warped. I called Flight Crafters and

Mexico and after what seemed like a very long time someone finally said I

would be receiving "the tap". I used it and eventually the neck would screw

in reasonably well. To this day the left tank doesn't screw in smoothly

because it was warped so badly. Only then did I find out about the problem

with the neck not screwing in far enough to allow for a flush fit. You

guessed it! Another set of phone calls and emails and long waiting until I

was told I would be receiving "the counter-sink". The wait could have been

longer but I would not ship back "the tap" until I got an answer. All in

all, this set me back quite a while on my "quick-build". I could expect this

if I were building from scratch or basic kit but when I paid the extra $$$$

for the quick-build kit I did expect some things to be taken care of. Don't

EVEN get me started on the "leather interior for a limited time"!!!!!!!!!!!!



Skip Perry

Fort Myers, Fl

601XL "quick-build" with many things to be discovered:-)



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