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  #1  
Old 11-26-2020, 03:28 AM
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fl9500 fl9500 is offline
 
Join Date: Apr 2013
Location: Hannover Germany
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Default Fuel tank repair kit - which saw for hole

Hi,

I will try to seal all five chambers of one of my RV6 tanks, which has many leaking rivets. with original VAN's "Fuel tank repair kit".

Which is the best saw-type to cut the big holes in the back of the fuel tank ?

What is the best method to reach all seams of the tank with the sealer ?

Thank you for all tips,
Achim
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  #2  
Old 11-26-2020, 06:21 AM
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Low speed, high torque drill, ordinary fly cutter. Go slow.
.
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  #3  
Old 11-26-2020, 07:12 AM
Southern Pete Southern Pete is offline
 
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+1, I built a wooden stand for the tank and positioned it under a pillar drill. Chain drilling takes ages and leads to lots of clean up.
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  #4  
Old 11-26-2020, 07:29 AM
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Default Harbor Freight

I used a standard hole saw kit from HF:

https://harborfreight.com/34-in-5-in...-pc-68115.html

Go slow RPM, use lots of bolube. Debur the edges after cutting. Worked great.
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Old 11-26-2020, 07:29 AM
Kyle Boatright Kyle Boatright is offline
 
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You could also do it with a router, using a jig as a guide.
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  #6  
Old 11-26-2020, 07:36 AM
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Quote:
Originally Posted by N520TX View Post
I used a standard hole saw kit from HF:

https://harborfreight.com/34-in-5-in...-pc-68115.html

Go slow RPM, use lots of bolube. Debur the edges after cutting. Worked great.
+ one for the HF hole saw set up for cutting the access holes. Tip: pre-drill the 1/4 pilot hole and use a steel dowel as the pilot in the hole saw. This helps keep the pilot from wondering and elongating/enlarging the pilot hole for clean round access holes.
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  #7  
Old 11-26-2020, 07:56 AM
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Drill a hole, then use an air nibbler. (Harbor Freight)
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  #8  
Old 11-26-2020, 08:07 AM
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I use a Craftsman fly cutter in my drill press. I hold the fuel tank in the assembly fixture used when I built the tanks. Clamp everything firmly. Verify the tool is square to the workpiece. Drill a #40 pilot hole. Set the drill press speed to the lowest rpm. Feed slowly.
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  #9  
Old 11-26-2020, 08:55 AM
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With either the hole saw or fly cutter, be sure that the center hole is riding on the smooth shank of the center drill bit when the cutter is actually working on the big hole.

If needed you can usually re-position the center/pilot drill bit out of the body a bit so the smooth shank is what the unit guides from when making the big hole.
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  #10  
Old 11-27-2020, 06:45 AM
Southern Pete Southern Pete is offline
 
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Quote:
Originally Posted by N520TX View Post
I used a standard hole saw kit from HF:

https://harborfreight.com/34-in-5-in...-pc-68115.html

Go slow RPM, use lots of bolube. Debur the edges after cutting. Worked great.
No HF stores in Germany :-(
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