Fuel filler 'condom'

[kevinh]

So out of curiosity/fun I thought I'd try 3d printing an insert for my fuel filler neck. To catch any overfill and let it drain out the bottom. This is just a test print but for the real thing I think it will work pretty well (though I guess I won't know for a few more months). I used a flexible fuel resistant plastic (TPU).

[Brett]

Looks good..... I ended up just riveting in some off cut Ali and sealing with a fuel proof sealant... amazing what these printers can make now. I love the air vents Peter printed and distributes for the Sonex also.

[DCASonex]

Looks great. If you find it holds up and want to make and sell more, likely no shortage of customers. I do not like metal plates for this as the neck does move slightly with variable fuel and G loads. I currently use a fabric re-enforced sheet of silicone material for this but difficult to keep bonded in place.

David A.

[WaiexN143NM]

Hi all, kevin,
Yes if you could make some more and take orders, if your willing, im sure we'd all like to order one!

WaiexN143NM
Michael

[sonexsteve]

I want one too! Please....

[Waiex 49]

Looks like a nice product. This would do a good job of fixing an engineering / design error on Sonex's part. Allowing a passage for spilt fuel to enter the cockpit is not good.

Your photo shows the part fitted to the fuel tank that has not been installed on the plane.

You might try installing it after the tank is in the aircraft and the filler neck is in the fuel filler box.

On my aluminum version, I had to re-do the main hole opening to be more of an oblong shape as the part had to go at an angle to get it into the fuel filler box and over the fuel filler neck.

Keep at it! I think you are on to something good that many builders would like to add to their Sonex aircraft.

[kevinh]

Yah - it seems to fit nicely in the aluminum neck (and it is flexible so you can squeeze it in). Alas - I'm not sure about selling them because this material is very slow to print (almost a day on the machine). If I did sell them I'd need to sell it at a pretty high price ($60 each).

[lstinthot]

Yah - it seems to fit nicely in the aluminum neck (and it is flexible so you can squeeze it in). Alas - I'm not sure about selling them because this material is very slow to print (almost a day on the machine). If I did sell them I'd need to sell it at a pretty high price ($60 each).

Would you be interested in sharing your file? What software are you using? Solidworks is free for EAA members. I have downloaded it, but not very proficient at it yet.

One place people are sharing files is here
https://grabcad.com/library/software/solidworks

Thanks,
Mike

[kevinh]

Sure - I added a link here (I've been using onshape because I like it better than solidworks): viewtopic.php?f=3&t=3909&p=29697#p29697