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Wingtank.com tank install, ongoing
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WurlyBird



Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

PostPosted: Mon Jan 04, 2010 7:54 pm    Post subject: Wingtank.com tank install, ongoing Reply with quote

I had heard several people mention the wingtank.com replacement tanks but I had not heard anyone mention actually having them. Well my wonderful, totally awesome, spectacular, and super cool wife got me a set for Christmas and I have just about collected all the bits needed for the install, I still need to get a spray gun and a compressor. I thought I would do a log of my installation for anyone who is interested in these tanks, I also thought it might be mildly beneficial/interesting since I have never worked with fabric and it has me a little scared still. Right now I am writing to the guys at wingtanks.com because the instructions come across as having been written by someone in a little hurry after having done their 50th similar install. There just seems to be a few things glossed over as if the directions are a formality and it all just falls together. I filled one of the tanks to rinse it out and I got a little short of 5 1/2 gallons in but this was from bone dry to filling the neck. I am trying to figure out whether I even need a sight tube fuel gauge and how to install one if I do. And I am also trying to work out a few other things but I will get to those as they start to make sense. I plan on doing one wing at a time and I figure I will be able to remove a wing and install a tank in about a day and it will probably take 2 weekends to finish the painting but only time will tell.

James

edited to better describe my wife


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Kitfox 3 / 582 / 70" IVO 2 blade GA
50 hrs on the 582 swapping for HKS 700E and Avid Cowl.


Last edited by WurlyBird on Tue Jan 05, 2010 6:23 pm; edited 2 times in total
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Fox5flyer
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PostPosted: Tue Jan 05, 2010 5:27 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

Great, James. Keep us updated.
Deke
Ps: congrats on your new ticket

Subject: Wingtank.com tank install, ongoing
Quote:

I had heard several people mention the wingtank.com replacement tanks but
I had not heard anyone mention actually having them. Well my wonderful
wife got me a set for Christmas and I have just about collected all the
bits needed for the install, I still need to get a spray gun and a
compressor. I thought I would do a log of my installation for anyone who
is interested in these tanks, I also thought it might be mildly
beneficial/interesting since I have never worked with fabric and it has me
a little scared still. Right now I am writing to the guys at
wingtanks.com because the instructions come across as having been written
by someone in a little hurry after having done their 50th similar install.
There just seems to be a few things glossed over as if the directions are
a formality and it all just falls together. I filled one of the tanks to
rinse it out and I got a little short of 5 1/2 gallons in but this was
from bone dry to filling the neck. I am trying to figure ou!
t whether I even need a sight tube fuel gauge and how to install one if I
do. And I am also trying to work out a few other things but I will get to
those as they start to make sense. i plan on doing one wing at a time and
I figure I will be able to remove a wing and install a tank in about a day
and it will probably take 2 weekends to finish the painting but only time
will tell.

James

--------
James
Kitfox 3 / 582 / GSC prop
The ink is still drying on my new certificate


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Tom Jones



Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA

PostPosted: Tue Jan 05, 2010 7:01 am    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

Quote:
I am trying to figure out whether I even need a sight tube fuel gauge and how to install one if I do.


I haven't seen these in person but looking at the picture on their web site I'd say you don't need a site gauge. You should be able to see the fuel through the end of the tank...I think.


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Dick Maddux



Joined: 24 Jun 2008
Posts: 516
Location: Milton, Fl

PostPosted: Tue Jan 05, 2010 7:36 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

James,
I for one would be very interested in your progress. Please take lots of pictures. I am kind of waiting for this bomb to explode in my aircraft as last week our last station in my area, switched to alcohol fuel and that's what I am forced to use. So if my filters start to clog I am faced with the route you have taken, rip my wings open and reslosh my tanks, or perhaps go to John McBean for a new set of hopefully alcohol resistant tanks. I am favoring the later but will be most interested in your endeavor.
        Dick Maddux
        Fox 4
        Milton,Fl
[quote][b]


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clint_bazzill(at)hotmail.
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PostPosted: Tue Jan 05, 2010 8:41 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

 Dick C
 
I have a Model IV.  Aug 1993 version.  Bare tanks C use alcohol fuel all the time.  Alsmost 1500 hours no problems. 
 
Clint
From: Catz631(at)aol.com
Date: Tue C 5 Jan 2010 10:11:08 -0500
Subject: Re: Wingtank.com tank install C ongoing
To: kitfox-list(at)matronics.com

James C
 I for one would be very interested in your progress. Please take lots of pictures. I am kind of waiting for this bomb to explode in my aircraft as last week our last station in my area C switched to alcohol fuel and that's what I am forced to use. So if my filters start to clog I am faced with the route you have taken C rip my wings open and reslosh my tanks C or perhaps go to John McBean for a new set of hopefully alcohol resistant tanks. I am favoring the later but will be most interested in your endeavor.
                                                     Dick Maddux
                                                     Fox 4
                                                     Milton CFl
[quote]

Quote:
http://www.matronics.com/Navigator?Kitfox-List
ronics.com

ww.matronics.com/contribution

[b]


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PostPosted: Tue Jan 05, 2010 8:54 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

Clint - what % ethanol in the fuel you've been using? What octane rating? It makes a *big* difference...


Bob Brennan - N717GB
ELSA Repairman, inspection rated
1991 UK Model 2 ELSA Kitfox taildragger
Rotax 582 with 3 blade GSC prop
Wrightsville Pa

From: owner-kitfox-list-server(at)matronics.com [mailto:owner-kitfox-list-server(at)matronics.com] On Behalf Of Clint Bazzill
Sent: Tuesday, January 05, 2010 11:30 AM
To: Kitfox list
Subject: RE: Wingtank.com tank install, ongoing


Dick,

I have a Model IV. Aug 1993 version. Bare tanks, use alcohol fuel all the time. Alsmost 1500 hours no problems.

Clint
From: Catz631(at)aol.com
Date: Tue, 5 Jan 2010 10:11:08 -0500
Subject: Re: Wingtank.com tank install, ongoing
To: kitfox-list(at)matronics.com

James,
I for one would be very interested in your progress. Please take lots of pictures. I am kind of waiting for this bomb to explode in my aircraft as last week our last station in my area, switched to alcohol fuel and that's what I am forced to use. So if my filters start to clog I am faced with the route you have taken, rip my wings open and reslosh my tanks, or perhaps go to John McBean for a new set of hopefully alcohol resistant tanks. I am favoring the later but will be most interested in your endeavor.
        Dick Maddux
        Fox 4
        Milton,Fl
[quote]

Quote:
http://www.matronics.com/Navigator?Kitfox-List
ronics.com

ww.matronics.com/contribution



href="http://www.matronics.com/Navigator?Kitfox-List">http://www.matronhref="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
[b]


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dave



Joined: 22 Sep 2006
Posts: 1382

PostPosted: Tue Jan 05, 2010 5:07 pm    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

[quote="Dick Maddux"]James,
I for one would be very interested in your progress. Please take lots of pictures. I am kind of waiting for this bomb to explode in my aircraft as last week our last station in my area, switched to alcohol fuel and that's what I am forced to use. So if my filters start to clog I am faced with the route you have taken, rip my wings open and reslosh my tanks, or perhaps go to John McBean for a new set of hopefully alcohol resistant tanks. I am favoring the later but will be most interested in your endeavor.
� � � � Dick Maddux
� � � � Fox 4
� � � � Milton,Fl
Quote:
[b]


Dick, I hope that you get good luck that I have had with ethanol gas. I have no sloshing in mine and really would not use it except for last resort.

I am too interested in the plastic tank install. seem like a great drop in application. I do have a fellow interested in them for his model 2 as he only has a dash tank. I just repaired his right wing after a ground loop into a bean field and ripped the flapperon off. 3 of the 5 rib ends were torn right off. Tanks outta budjet now for him but maybe in the near future. I test flew it a week ago and works well Smile


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WurlyBird



Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

PostPosted: Tue Jan 05, 2010 6:20 pm    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

Anyone that has read any of my recent posts knows that I am having fuel concerns and I have been trying to figure out the lesser of the two evils between ethanol and lead. Aside from this issue I have experienced a leak in one of my tanks if filled above half full. I have been using this tank to only hold a couple gallons unless I am going on a long flight but this was a temporary solution. Both tanks have obviously leaked or sloshed out at some time and the fabric underneath them is ruined.

So I have concerns about the available fuels in my area, one tank is leaking, and the fabric on the wings REALLY needs to be replaced anyway. It is not too hard to come to the conclusion of simply replacing the tanks.

Price was certainly one of the big factors in deciding to go with these tanks over John McB's. I am immediately pleased with these tanks and their construction. They look very sound and robust. The fuel outlets are of a different configuration then I would have expected. You drill a hole, put a hollow, top hat shaped grommet into the dole and then force the outlet into the grommet which then uses pressure to seal the hole. As I mentioned in my first post I had some concerns with the directions and I sent them an email full of questions. All questions have been answered in less then a days time and I was told that the directions are what were handed over when the company changed hands and that all suggestions are welcome regarding them. I will try to make a post every day that I am able to work on the project and I will try to take a bunch of pictures and post the pertinent ones.

James


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Kitfox 3 / 582 / 70" IVO 2 blade GA
50 hrs on the 582 swapping for HKS 700E and Avid Cowl.
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WurlyBird



Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

PostPosted: Thu Jan 07, 2010 6:40 pm    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

Here is what is sure to be the first of many questions during this install. I am almost done reading the Poly-Fiber manual and it mentions that a PF sealer needs to be used any time securing fabric to wood, fine. The guys at wingtanks.com are telling me that I do not need to use any sealer and I can simply glue down the plywood covers, apply fabric and paint. What are your thoughts on this?

Having gotten into this manual, and now my wing, I have come to realize that my Kitfox does not have rib stitching on it's overcambered wing which according to PF should certainly have stitching. I have not pulled out the build manual yet but I was wondering if this is normal for the KF.

I have some pictues of the damaged fabric on one wing and I will post them once I get into the wing and have more pictures worth posting.

James


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Paul A. Franz, P.E.



Joined: 02 Dec 2008
Posts: 280
Location: Bellevue WA

PostPosted: Thu Jan 07, 2010 8:34 pm    Post subject: Wingtank.com tank install, ongoing Reply with quote

On Thu, January 7, 2010 6:40 pm, WurlyBird wrote:
Quote:


Here is what is sure to be the first of many questions during this install. I am
almost done reading the Poly-Fiber manual and it mentions that a PF sealer needs to be
used any time securing fabric to wood, fine. The guys at wingtanks.com are telling me
that I do not need to use any sealer and I can simply glue down the plywood covers,
apply fabric and paint. What are your thoughts on this?

Always follow PolyFiber's instructions. They trump anyone else's. If in doubt phone
them, they are of the utmost help and support. They cheerfully answer questions. They
have even sent me extra stuff without charging when I only needed little.

Quote:
Having gotten into this manual, and now my wing, I have come to realize that my Kitfox
does not have rib stitching on it's overcambered wing which according to PF should
certainly have stitching. I have not pulled out the build manual yet but I was
wondering if this is normal for the KF.

This has been discussed frequently over the years. Screws and rivets have very often
been used successfully by themselves however rib lacing is by far the most preferred
way. Rib lacing is a quickly learned skill and each time I have done it, I had to go
back to the manual to learn it again. I think it added less than 10 total hours for
all of it that I did on both wings and in several other places in the tail feathers
and landing gear struts.

I encourage you to rib lace where you are recovering. I wouldn't bother removing
covering just to rib lace as long as it otherwise doesn't require recovering. Most
flight shows this spring will have a Poly Fiber clinic where you can practice with
supervision. The manual shows you how to tie the knots and hide them using good
drawings so that will just be a fun new thing to learn and do for you.
--
Paul A. Franz
Registration/Aircraft - N14UW/Merlin GT
Engine/Prop - Rotax 914/NSI CAP
Bellevue WA
425.241.1618 Cell

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PostPosted: Thu Jan 07, 2010 9:52 pm    Post subject: Wingtank.com tank install, ongoing Reply with quote

James,

I did a bit of research a couple of days ago regarding the Steve Wittman
crash. His Tailwind had plywood skinned wings with fabric over the plywood.
He used dacron fabric and a cotton fabric / dope to attach the fabric to the
wood. After ten years flying his airplane, the fabric separated just
forward of the aileron and the resulting flutter destroyed the airplane in
flight. In other words, he didn't use proper procedures.

For my money, in this situation, I think I would pay some attention to the
fabric guys - unless, of course, the tank guys are very rich or have great
liability insurance.

Regarding the ribstitching - I believe ribstitching was very rare in the
early Kitfoxes. My 1993 Model IV manual said nothing about rib stitching.
I did it though because of talk on the Kitfox list back then. If I were to
guess, I suspect not four or five out of a hundred were rib stitched -
again, in the early Kitfoxes. I suspect when others read your post, some I
through III pilots might chime in with more authoritative info.

Lowell

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PostPosted: Fri Jan 08, 2010 8:46 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

James,
 
My Model 2 is not rib-stitched. I did not cover and paint myself but I did carefully review every line of the builders logs and published instructions after purchasing the project. As I recall, Kitfox did not then (early '90's) recommend rib stitching, advising that the 1" cap strips on the ribs provided a sufficient glue surface to hold down the fabric without stitching


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larry huntley



Joined: 19 Jul 2008
Posts: 149

PostPosted: Fri Jan 08, 2010 8:47 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

Sealer is quick and cheap and may prevent wood rotting or whatever later
on. Can't think of any reason to not do it.
Same w/ ribstitching. I ribstitched my 4-1200 and I wouldn't fly a Kitfox
without it. Not that you shouldn't if you so desire, just that I won't. Not
to bad a project to pull the tapes ,stitch, replace new tapes.
Learning the Modified seine knot that most use in ribstiching takes a bit
of time and it is a slow process after you lean. You can ,hoever, use the
Beechcraft Staggerwing knot that is much easier and faster. The Sewart
Systems process has this written into their Manual and STC for certified
aircraft. FWIIW, the Stewart System can be used over any other process for
repairs and the ce,ent and paint,etc. will not react with other materials
like dope or poly will. I have written this in terms of certified aircraft,
but of course ,if is will be acceptable on certified it is acceptable on
Experimental. http://www.stewartsystems.aero/
Check their site above. I have been using their materials for over 5 yrs and
am very pleased with it.
Larry Huntley A&P ,4-1200 EA-81,Warp,AMAX redrive,
500+ hrs
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PostPosted: Fri Jan 08, 2010 9:15 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

the truth about the need to rib stitch is buried in the need for poly fiber to cover their hinder and the kit mfgr. to make his kit appear as quick to build as possible. poly fiber states in their manual it is imperative to rib stitch ''even with 1 inch wide rib caps''.
               bob noffs
On Fri, Jan 8, 2010 at 10:21 AM, Larry Huntley <asq(at)roadrunner.com (asq(at)roadrunner.com)> wrote:
[quote]--> Kitfox-List message posted by: "Larry Huntley" <asq(at)roadrunner.com (asq(at)roadrunner.com)>

 Sealer is quick and cheap and may prevent wood rotting or whatever later on. Can't think of any reason to not do it.
 Same w/ ribstitching. I ribstitched my 4-1200 and I wouldn't fly a Kitfox without it. Not that you shouldn't if you so desire, just that I won't. Not to bad a project to pull the tapes ,stitch, replace new tapes.
 Learning the Modified seine knot that most use in ribstiching takes a bit of time and it is a slow process after you lean. You can ,hoever, use the Beechcraft Staggerwing knot that is much easier and faster. The Sewart Systems process has this written into their Manual and STC for certified aircraft. FWIIW, the Stewart System can be used over any other process for repairs and the ce,ent and paint,etc. will not react with other materials like dope or poly will. I have written this in terms of certified aircraft, but of course ,if is will be acceptable on certified it is acceptable on Experimental.  http://www.stewartsystems.aero/
Check their site above. I have been using their materials for over 5 yrs and am very pleased with it.
                       Larry Huntley A&P ,4-1200 EA-81,Warp,AMAX redrive, 500+ hrs
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PostPosted: Fri Jan 08, 2010 10:08 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

For what it is worth, my very recent experience with rib stitching amounts
to approximately the following.

Measuring and marking the stitch locations with a chalk line and punching
the holes about half an hour each wing
Positioning the reinforcing tape about an hour each wing
Rib stitching about a day each wing ( I did rib stitch under the wing tank
and under my aluminum leading edge - a bit more challenging)
Then there is the long finish tape over the spar, that needed to be
sectioned rather than applied in one continuous strip to avoid crossing the
reinforcing tape an additional half hour.

Total about three days.

Cost about $100 for the reinforcing tape and $50 for the rib lace cord.

Worth it? To me yes.

Lowell

In short, I think I have
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Pat Reilly



Joined: 06 Aug 2009
Posts: 345

PostPosted: Fri Jan 08, 2010 1:12 pm    Post subject: Wingtank.com tank install, ongoing Reply with quote

James, I would difinitely seal the wood. It will resist moisture. Nothing will make it "Waterproof". I had the same question when I rebuilt my Mod 3. I can't remember if I settled on varnish or used West System Epoxy to seal. I know I thought about varnish and usually have West resin on hand. The aircraft suppliers sell 2 part varnishes that cost a gizzillian $. I needed maybe a 1/2 pint What ever I used I tested it with PF product to make sure they were compatible.
 
Pat Reilly
Mod 3 582 Rebuild
Rockford, IL 
On Thu, Jan 7, 2010 at 8:40 PM, WurlyBird <james.t.trizzino(at)us.army.mil (james.t.trizzino(at)us.army.mil)> wrote:
[quote]--> Kitfox-List message posted by: "WurlyBird" <james.t.trizzino(at)us.army.mil (james.t.trizzino(at)us.army.mil)>

Here is what is sure to be the first of many questions during this install.  I am almost done reading the Poly-Fiber manual and it mentions that a PF sealer needs to be used any time securing fabric to wood, fine.  The guys at wingtanks.com are telling me that I do not need to use any sealer and I can simply glue down the plywood covers, apply fabric and paint.  What are your thoughts on this?

Having gotten into this manual, and now my wing, I have come to realize that my Kitfox does not have rib stitching on it's overcambered wing which according to PF should certainly have stitching.  I have not pulled out the build manual yet but I was wondering if this is normal for the KF.

I have some pictues of the damaged fabric on one wing and I will post them once I get into the wing and have more pictures worth posting.

James

--------
James
Kitfox 3 / 582 / GSC prop
The ink is still drying on my new certificate


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akflyer



Joined: 07 May 2007
Posts: 574
Location: Soldotna AK

PostPosted: Fri Jan 08, 2010 1:21 pm    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

When I got my plane it was not rib stitched. for peace of mind, I stitched it when I rebuild it. The polyfiber manual I have says you dont have to ribstitch UNDERCAMBERED wings, but you need to be very careful and not shrink to the full temp or it could pull away. Total time for me to cover, layout, stitch, tape, shrink and have ready to shoot silver was one day each wing. The third day was shooting silver and top coat.

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Leonard Perry aka SNAKE
Soldotna AK
Avid "C" / Mk IV
582 (147 hrs and counting on the rebuild)
IVO IFA
Full Lotus 1450
#1 snake oil salesman since 1-22-2009

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Pat Reilly



Joined: 06 Aug 2009
Posts: 345

PostPosted: Fri Jan 08, 2010 3:56 pm    Post subject: Wingtank.com tank install, ongoing Reply with quote

Len, My God, I wished you lived close by. I'd hire you by the hour to cover the wings on the next one I build.
 
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Pat Reilly
Mod 3 582 Rebuild
Rockford, IL
On Fri, Jan 8, 2010 at 3:21 PM, akflyer <akflyer_2000(at)yahoo.com (akflyer_2000(at)yahoo.com)> wrote:
[quote]--> Kitfox-List message posted by: "akflyer" <akflyer_2000(at)yahoo.com (akflyer_2000(at)yahoo.com)>

When I got my plane it was not rib stitched.  for peace of mind, I stitched it when I rebuild it.  The polyfiber manual I have says you dont have to ribstitch UNDERCAMBERED wings, but you need to be very careful and not shrink to the full temp or it could pull away.  Total time for me to cover, layout, stitch, tape, shrink and have ready to shoot silver was one day each wing.  The third day was shooting silver and top coat.

--------
DO NOT ARCHIVE
Leonard Perry aka SNAKE
Soldotna AK
Avid "C" / Mk IV
582 (87 hrs and counting on the rebuild)
IVO IFA
Full Lotus 1450
#1 snake oil salesman since 1-22-2009

I would rather die trying to live, than to live trying not to die....


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akflyer



Joined: 07 May 2007
Posts: 574
Location: Soldotna AK

PostPosted: Fri Jan 08, 2010 7:36 pm    Post subject: Re: Wingtank.com tank install, ongoing Reply with quote

when I get on a project i dont stop for anything... 5:00 am in the shop, quit when your done.. Things progress quickly like that.

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_________________
DO NOT ARCHIVE
Leonard Perry aka SNAKE
Soldotna AK
Avid "C" / Mk IV
582 (147 hrs and counting on the rebuild)
IVO IFA
Full Lotus 1450
#1 snake oil salesman since 1-22-2009

I would rather die trying to live, than to live trying not to die....
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Pat Reilly



Joined: 06 Aug 2009
Posts: 345

PostPosted: Sat Jan 09, 2010 7:07 am    Post subject: Wingtank.com tank install, ongoing Reply with quote

Len, Still hittin it at 5:00am. I'm jealouse. I'm getting lazy as I get older. Curious, how old are you?
Do not archive
Pat Reilly
Mod 3 582 Rebuild
Rockford, IL
On Fri, Jan 8, 2010 at 9:36 PM, akflyer <akflyer_2000(at)yahoo.com (akflyer_2000(at)yahoo.com)> wrote:
[quote]--> Kitfox-List message posted by: "akflyer" <akflyer_2000(at)yahoo.com (akflyer_2000(at)yahoo.com)>

when I get on a project i  dont stop for anything... 5:00 am in the shop, quit when your done..  Things progress quickly like that.

--------
DO NOT ARCHIVE
Leonard Perry aka SNAKE
Soldotna AK
Avid "C" / Mk IV
582 (100 hrs and counting on the rebuild)
IVO IFA
Full Lotus 1450
#1 snake oil salesman since 1-22-2009

I would rather die trying to live, than to live trying not to die....


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