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Fuel Filler Cap

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bressler(at)wyoming.com
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Posted: Sun Aug 13, 2006 3:00 pm Post subject: Fuel Filler Cap

Thread Listers:  We are 601XL kit builders and  have encountered problems fitting the 15 gallon fuel tanks in the nose skin. The  top of the fuel filler threaded bushing,P/N M142, pg. 6-K-1, is flush with the  seam welds on the tank end and back. Cinching the nose skin to final position  leaves the bushing surface 2-3 mm below the skin and leaves the filler cap 8-10  mm above the skin.

 The threaded fuel filler insert that holds the cap  is larger than the bushing and is unthreaded for the upper 10 mm; this leaves  the cap 7-8 mm above the skin with an unsealed opening.

 Has anyone else had this problem? What solutions  are acceptable to bring the cap down to the skin and or seal the  opening?

  

 Looking through the quick drain and vent holes in  the bottom of the nose skin the tank appears to be sitting on the cork strips.  We've called ZAC and talked with Nick. One solution recommended was to bevel the  surface of the threaded bushing to allow the insert to drop, but he cautioned  that would only work for a 3-4 mm depth, leaving the filler cap about 4 mm above  the skin. He also indicated if no satisfactory solution could be achieved, the  tanks could be shipped back to the factory for retrofitting. He indicated that  the factory was presently welding the threaded bushing slightly  lower.

 Thank you all for your participation on these  builder questions.

  

 Wes & Lurlene Bressler; bressler(at)wyoming.com (bressler(at)wyoming.com)

 Empenage done; working on the hard  wing

 601WL in Laramie, WY

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dredmoody(at)cox.net
Guest

Posted: Mon Aug 14, 2006 5:36 am Post subject: Fuel Filler Cap

If they offered you the option of refitting the tanks, you should definitley take that them up on it. I just finished grinding a bevel into the female threaded rings on both tanks on my 601XL for the reason you stated. 



The first one I did was a real struggle. The threads got fouled and I ended up buffing the threads off both male and female parts and ProSealing the filler neck into place when I closed up that wing.



The secong one went better and I was able to preserve the integrity of the threads so it will install normally when I close this wing in a few more days. 



Wouldn't you know, I waited to contact Zenith about the issue (stupid me) until last week to suggest that they weld the female ring under the upper tank skin  only to find out that they had already begun fitting it that way. If I had known that earlier, I would not have sweated through the beveling operation.



Ed Moody II

Rayne, LA

601XL / 2nd wing



 

---- Wes or Lurlene Bressler <bressler(at)wyoming.com> wrote: 

 	  Quote: 	
		   Thread Listers:  We are 601XL kit builders and have encountered problems fitting the 15 gallon fuel tanks in the nose skin.

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601zv(at)ritternet.com
Guest

Posted: Mon Aug 14, 2006 6:59 am Post subject: Fuel Filler Cap

I have 4 tank caps to do on my 601xl. Does anyone  have a clever way to cut or grind a nice smooth bevel without chucking the  wing in a giant lathe?

 [quote]   ---

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rsq2424(at)yahoo.com
Guest

Posted: Mon Aug 14, 2006 9:41 am Post subject: Fuel Filler Cap

Anyone have a picture of these thread rings everyone is talking about? I have an older model of the XL and there's no such thing. I'd be surious to see if that's a better solution than what I ended up with, because I too have a gap between the skin and the filler neck.

   

  Mike Fortunato

   

  do not archive



dredmoody(at)cox.net wrote:

   	  Quote: 	
		  --> Zenith-List message posted by: 



 just finished grinding a bevel into the female threaded rings on both tanks on my 601XL for the reason you stated. 



The first one I did was a real struggle. The threads got fouled and I ended up buffing the threads off both male and female parts and ProSealing the filler neck into place when I closed up that wing. 	


  [quote][b]

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ding(at)tbscc.com
Guest

Posted: Mon Aug 14, 2006 4:34 pm Post subject: Fuel Filler Cap

Robin,

             I used  a straight 1/2 inch dia. router bit in a handheld high speed grinder. It doesn't  look like a lathe cut, but it cut clean and did minimal damage to the internal  threads.

                                                                     Lynn

                                                                     Corry, PA

                                                                     601XL / Corvair     empennage and wings done (and engine)

   [quote][b]

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