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fuel sender access covers

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bradfnp(at)msn.com
Guest

Posted: Mon Mar 27, 2006 7:01 pm Post subject: fuel sender access covers

Hello all

awhile back there was a discussion regarding the fabrication of access plates to cover the fuel senders on the 601xl wings.



 	  Quote: 	
		  From what I can recall, most of you suggested filing down the threads on the contact screw to allow clearance from the upper skin.  I do recall one person saying that he scratch built a domed cover for his senders.


	


I have the new senders with the bayonette connector (not the old style with a nut that can be filed down) and now have a similar problem, the connector now protrudes from the upper surface of the wing skin.



is the person who made those access plates still involved witht eh listserv? is he or she willing to contact me off line at bradfnp(at)msn.com<mailto:bradfnp(at)msn.com> to tell me how he or she made the domed covers or where I can find similar plates? does anyone have any suggestions?



brad cohen

601xl

working on the wings....

p.mulwitz(at)worldnet.att
Guest

Posted: Mon Mar 27, 2006 8:45 pm Post subject: fuel sender access covers

The fuel tank design makes more room available for the sender wiring 

near the spar than farther forward.  You might have better luck if 

you place the sender in the area that has more space.  You can 

connect a female spade connector to the one on the new sender.  These 

can be found with built in insulators.



Good luck,



Paul

XL wings



 	  Quote: 	
		  I have the new senders with the bayonette connector (not the old 

style with a nut that can be filed down) and now have a similar 

problem, the connector now protrudes from the upper surface of the wing skin.

nfivesl(at)yahoo.com
Guest

Posted: Tue Mar 28, 2006 5:44 am Post subject: fuel sender access covers

Brad:



How is the bayonet connector attached to the top of

the sender?  Maybe you already thought of this, but if

it is riveted, can't you just drill out the rivet and

put a small screw and nut there?  I had to take mine

all apart and weld the extension to the face plate

because I was getting an intermittent loss of ground. 

Here's a photo of it welded:

http://www.cooknwithgas.com/3_04_03_Sender2.JPG

and here it is ready for installation:

http://www.cooknwithgas.com/3_5_03_SenderParts.JPG



If you could drill out the rivet holding the assembly

together, you could install a screw and two nuts and

use the same kind of connection I used.  (One nut

holds the assembly together and the other holds the

electrical connector.)  Just make sure you get all the

insulators back in the right order and you should be

good to go with a screw and nuts.

http://www.cooknwithgas.com/5_30_04_Wingholes.JPG



I hope this helps,



Scott Laughlin

www.cooknwithgas.com

Plumbing intake piping

--- Brad Cohen <bradfnp(at)msn.com> wrote:



 	  Quote: 	
		   I have the new senders with the bayonette connector

 (not the old style with a nut that can be filed

 down) and now have a similar problem, the connector

 now protrudes from the upper surface of the wing

 skin.

rsq2424(at)yahoo.com
Guest

Posted: Tue Mar 28, 2006 9:58 am Post subject: fuel sender access covers

 	  Quote: 	
		   I do recall one person saying that he scratch built a domed 

 cover for his senders.


	


If you get an answer on that, I would like to know as well. I have the same problem, but haven't tackled it yet (low on the priority list). Filing down the terminal didn't work for me, nor any of the other tricks previously mentioned, so I will also need some sort of domed covers.



do not archive



		

---------------------------------

601zv(at)ritternet.com
Guest

Posted: Tue Mar 28, 2006 10:51 am Post subject: fuel sender access covers

I too have been puzzling over this for some time. Unless someone comes up 

with a better idea, my plan is to use standard aluminum Inspection Plates 

(ACS #09-19300). They are 5" in diameter and the center of the dome rises 

about 8mm, so they should just fit with the metal spring clip removed. Also, 

on my four tanks, not only do the senders protrude above the top skin, but 

when the filler cap receptacles are screwed in they seat in the tank before 

fully contacting the skin leaving a slight gap. Have any of you also noticed 

this, and have a fix for it (some sort of rubber gaskety ring or something 

to take up the slack)?



---

Tim Juhl

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

Posted: Tue Mar 28, 2006 1:45 pm Post subject: Re: fuel sender access covers

I'm confused....  I haven't received my kit yet, but a look at the drawings (dated 8/05) show the sender for the tank installed on the inboard end, not the top.  Can someone explain things to a newbie?



Tim

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

601zv(at)ritternet.com
Guest

Posted: Tue Mar 28, 2006 2:26 pm Post subject: fuel sender access covers

Older plans showed installation in the top. Apparently rather than change 

the tank design to make them fit on top, they revised the plans to put them 

in the ends of the tank. I considered putting them in the end to avoid the 

bulges on top of the wing, but decided to go with the top access so they 

would be easier to service.



---

pmaxpmax(at)hotmail.com
Guest

Posted: Wed Mar 29, 2006 10:16 am Post subject: fuel sender access covers

I made two covers that had a sort of a tit in the middle of them.  I drilled 

a hole in a board about an inch across, smoothed the edges and then used a 

broom handle to pound a protrusion into the aluminum.  When I was satisfied, 

I cut them round and put felt inside to ensure they didn't ground on the 

sender.  My plane will be at Sun-n-Fun for your inspection.



Phil Maxson

N601MX

601XL/Corvair

 	  Quote: 	
		   > I do recall one person saying that he scratch built a domed

 > cover for his senders.



If you get an answer on that, I would like to know as well. I have the same 

problem, but haven't tackled it yet (low on the priority list). Filing down 

the terminal didn't work for me, nor any of the other tricks previously 

mentioned, so I will also need some sort of domed covers.

ggower_99(at)yahoo.com
Guest

Posted: Wed Mar 29, 2006 3:39 pm Post subject: fuel sender access covers

Hello Phil, 

  Good idea, will try it, but also some of us that will not go to S&F  will appreciate some photos...  Thanks a lot.

  Saludos

  Gary Gower.

  701 912S

  Flying from Chapala  

Start building a 601 XL.

  Do not archive.

Phil Maxson <pmaxpmax(at)hotmail.com> wrote:

I made two covers that had a sort of a tit in the middle of them. I drilled 

a hole in a board about an inch across, smoothed the edges and then used a 

broom handle to pound a protrusion into the aluminum. When I was satisfied, 

I cut them round and put felt inside to ensure they didn't ground on the 

sender. My plane will be at Sun-n-Fun for your inspection.

Phil Maxson

N601MX

601XL/Corvair

 	  Quote: 	
		   > I do recall one person saying that he scratch built a domed

 > cover for his senders.

If you get an answer on that, I would like to know as well. I have the same 

problem, but haven't tackled it yet (low on the priority list). Filing down 

the terminal didn't work for me, nor any of the other tricks previously 

mentioned, so I will also need some sort of domed covers.

---------------------------------

goodings(at)yorku.ca
Guest

Posted: Thu Mar 30, 2006 6:44 am Post subject: Fuel Sender Access Covers

We made a nice cover for our fuel sender in the header tank of our 601

using fibreglass to cover a chemist's watchglass (but a child's ball of

suitable diameter would be just as good, to use as a mold; I've also seen

someone use the bottom of a jar, taking advantage of the curved-up

perimeter).  A 3/4 inch hat brim was added later.  This has the advantage

of being able to sand the hat brim to fit the curvature of the turtle deck

exactly (or the wing curvature in the case of wing tanks).  The hat brim

was formed initially by laying a sheet of wax paper over the turtle deck.

The circular cover is held in place by 8 small sheet metal screws.  A

nitrile ring gasket about 3/4 inches wide provides a bit of compression

spring to hold the sheet metal screws in place, and seals against rain.

This took a bit of time to make.  The end product is nice.  We all have

our own ways of wasting time!



John Goodings, C-FGPJ, CH601HD with R912S, Toronto/Waterloo.

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