Sonex Fuel Tank & Oops Fittings

Have you spun the fittings in your Sonex (roto-molded) fuel tank?

Yes, and I repaired it with an Oops fitting
10
33%
Yes, and I repaired/sealed it with a different method
7
23%
No, I am still using the original fittings
13
43%
 
Total votes : 30

Re: Sonex Fuel Tank & Oops Fittings

Postby GordonTurner » Fri Sep 29, 2017 9:59 pm

I have just received the tools from Ben.

Who's next?

Gordon
Waiex 158 New York. N88YX registered.
3.0 Liter Corvair built, run, and installed.
Garmin panel, Shorai LiFePo batteries.
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Re: Sonex Fuel Tank & Oops Fittings

Postby rizzz » Sun Oct 01, 2017 6:16 pm

OK, so far so good.
I filled the tank and left it overnight, no leaks.
I then went for a fly, did some aero's and pulled quite a few G's, still no leaks.
The fix seems to work so far.
I will report back here in a few weeks time with an update.

For the people interested in how this fix is done, the pictures I posted show the idea but just in case here's an explanation (of course this is not a Sonex approved fix and should be done at your own risk!):
1: make little plates out of 1/8 6061, about 1" larger than the fitting they will go around. You can make these plates square or octagon shape or something like that, the idea is you can use a spanner on them to tighten them against the tank.
2: drill and tap a hole so the plate can be screwed onto the NPT fitting. make sure you tap it far enough so it can be screwed all the way to the back.
3: with the plate on the NPT fitting, cover the contacting side in Permatex #3 Aviation Form-a-Gasket and screw the NPT fitting into the molded fitting in the tank, tighten as per normal.
4: turn the plate back on the fitting until it contacts the tank & molded fitting, tighten slightly using a spanner.
5: leave overnight before putting fuel in the tank (I did anyway).
Michael
Sonex #145 from scratch (mostly)
Taildragger, 2.4L VW engine, AeroInjector, Prince 54x48 P-Tip
VH-MND, CofA issued 2nd of November 2015
First flight 7th of November 2015
Phase I Completed, 11th of February 2016
http://www.mykitlog.com/rizzz/
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Re: Sonex Fuel Tank & Oops Fittings

Postby Waiex 49 » Sun Oct 01, 2017 6:23 pm

Hi Michael,

Nice job on that repair!

Professional looking workmanship.

Thanks for sharing this.
Waiex 49
 

Re: Sonex Fuel Tank & Oops Fittings

Postby BRS » Thu Oct 26, 2023 9:11 pm

OOPS!

When I renovated my Sonex-A I had installed a fitting in the fuel tank outlet with plans to eventually replace it. It needed to be replace with a screened fitting.

Today while making that change I ran into a delima. The fitting would not come out (did I use loctite? Don't remember). So I could keep pulling on the wrench and either it would give or the fuel tank insert would give. Either way, there needed to be a screen in there. Well since I'm posting on this thread, you can guess it was the insert that gave in first. Spun two flats.

Good thing, I pre-emptively purchased a set of OOPS fittings a few years ago. Bad thing, the AN fitting is still in the tank insert and is in the way. So now what? All I can think is to drill through it with a 1/2 step bit at which point it should break off. Any other ideas?

Also, after reading the instructions and the first 5 pages (10 pages to go) of this thread I'm still questioning the need for the 1" drill bit. My Step bit stops at 1" then can be just pushed through. Will that not leave a clean enough hole?

Thanks!
Attachments
OOPS-needed.jpg
-Brock
Sonex-A (s/n 1013)
R2300, P-tip 54/50
Center Stick
V16, TT22
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Re: Sonex Fuel Tank & Oops Fittings

Postby Bryan Cotton » Thu Oct 26, 2023 9:43 pm

I preemptively installed oops fittings. I took a regular fitting and drilled a hole in it to use as a guide for a holesaw. Worked great. You could do something similar.
viewtopic.php?f=33&t=1916&hilit=oops+fitting&start=40

Either a bushing, or a stepped rod that matches the ID of the AN fitting.

Edit: here is another picture.
Oops fitting holesaw setup.jpg
Oops fitting holesaw setup.jpg (50.83 KiB) Viewed 9440 times
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Re: Sonex Fuel Tank & Oops Fittings

Postby BRS » Thu Oct 26, 2023 11:28 pm

Thanks Bryan,
I had seen your post as I read through the thread but didn't realize what you were showing. I understand now. Might do it that way.

-brs
-Brock
Sonex-A (s/n 1013)
R2300, P-tip 54/50
Center Stick
V16, TT22
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BRS
 
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Re: Sonex Fuel Tank & Oops Fittings

Postby Bryan Cotton » Thu Oct 26, 2023 11:34 pm

The holesaw will either go around that AN fitting or saw right through it.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Re: Sonex Fuel Tank & Oops Fittings

Postby DCASonex » Fri Oct 27, 2023 8:54 am

I have the OOPs fitting tool kit that I made up some years ago. Many others have used it and added to it. PM me your mailing address, and I will send it out Priority Mail. (assuming you are in the US). When returning, just include cost of my shipping it out.

David A.
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Re: Sonex Fuel Tank & Oops Fittings

Postby Bryan Cotton » Fri Oct 27, 2023 8:59 am

DCASonex wrote:I have the OOPs fitting tool kit that I made up some years ago. Many others have used it and added to it. PM me your mailing address, and I will send it out Priority Mail. (assuming you are in the US). When returning, just include cost of my shipping it out.

David A.

That tool is awesome! Glad to see it is still making the rounds. Thanks David!
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Sonex Fuel Tank & Oops Fittings

Postby BRS » Fri Oct 27, 2023 9:18 am

DCASonex wrote:I have the OOPs fitting tool kit that I made up some years ago. Many others have used it and added to it. PM me your mailing address, and I will send it out Priority Mail. (assuming you are in the US). When returning, just include cost of my shipping it out.

David A.


Thank you David. Yes your tool seems to have quite the reputation. PM sent.
-brs

PS. I'm not sure what all is in your kit. Should I hold off on drilling my hole unti it arrives?
-Brock
Sonex-A (s/n 1013)
R2300, P-tip 54/50
Center Stick
V16, TT22
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