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Zenith CruZer & Sonex Logs
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Date:  5-6-2018
Number of Hours:  2.50
Manual Reference:  C85-KA-1
Brief Description:  Leak test fuel tank, block extra port, rivet brace

Since I'm using a Continental O-200 engine, I have no need for a fuel return line (used with injected engines), so obtained brass plugs (1 for each tank) to block 'em off. The plugs I bought yesterday would not work - they were hollow inside, all the way up to the crown of the square top. This is only a problem because one must cut-down the square wrench point to fit between the ribs. Returned the plugs to Lowes and went to Home Depot. They had plugs that were full cast, so bought those. Brought them home and cut the top of one with my band saw, using vise grips to hold it. That plug was super-hot! It melted the plastic blade spacer in the saw table! Had to spend time chipping-out plastic from the thread of the plug!

I also decided to leak-test the tank in the area where I installed the fuel sending unit. Since the tank only had red plastic plugs in the currently-open ports (fuel supply line, tank sump point, and return line port, I blocked one end of the tank to keep it from sliding off the table, then using boxes and wood blocks canted the tank at an angle to keep fuel away from the unsealed ports. No leaks! Note that this was done outside; really didn't want to see my project go up in flames if something went wrong.

Nexit, I riveted an internal bracket/spacer to the tank bay floor; since the wings have a dihedral to them , the tanks are welded with the inner side shallower than the outside edge. This spacer just helps keep the tank level with respect to the wing mounting.

Lastly, installed the trailing edges. These took some finagling; they're supposed to be mounted so the trailing edge is 80mm above the flaperon attach brackets; the outer skin was a bit out of adjustment (pre-drilled, final-sized holes, so no wiggle room). Remove cleco's and "encouraged" the skins a bit to get to 79mm; I figure this is close enough, but will check with Zenith in the AM.
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Fuel return line port blocked

Fuel return line port blocked

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angled tank to keep from leaking open ports

angled tank to keep from leaking open ports

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tank bracket / spacer

tank bracket / spacer

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