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Prefabricated Fuel Tank

NZ_Pompey

Member
Whilst I await my Emp & Wing kits to ship I am getting ready to order the Fuse kit, but can't decide whether to also order the pre-made fuel tank or just build it myself.

For those that have gone before - if you done it over would you build it again yourself, or go with the $600 pre-built option? And how much time would this save?

Reading a few threads I know it looks like one of the messier jobs on the build but my main concern is having to chase around finding & fixing leaks, but again i'm not sure how much of a problem this is in reality?

Thanks!
Paul
 
Buy a quart pack of pro seal from Van’s. it really isn’t a big deal doing it yourself. There’s no guarantee on the prefabbed tank anyway. Pro seal is not as scary as people seem to think. Make sure you have everything ready before you start. And go for it. I actually enjoyed the challenge. Attack it in the tradesmanlike way you kiwis are noted for, and there is really no reason that you will be “chasing leaks.”
As for time...took maybe about 4 hours.
Cheers, DaveH
120485
 
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The prefab RV-12 tanks are built (and then leak tested) with pride right here at the Van's Aircraft facility in Aurora Oregon. They guys that do the work have built hundreds of tanks.
They are used in all production SLSA RV-12's and are offered to RV-12 home builders as an option.

The alternative of course is to build it yourself. Many hundreds of builders have done so successfully by carefully following the KAI instructions.
 
I concur with DaveH above. The whole tank building process seems daunting at first but once you start it is just like any other aspect of building. Plan and prep ahead -- think like a leak and anticipate where and how fuel might want to escape its confines (it's a Zen thing). Use plenty of popsicle sticks, disposable gloves, syringes, and masking tape. Build the tank in sections so you don't get too stressed or rushed trying to assemble the whole thing in one sitting. Be neat and endeavor to keep things clean. Don't overapply the sealant -- more sealant will not necessarily prevent leaks. Enjoy the journey and learn a new skill.
 
Just buy the pre built tank.......

Any skilled task, whether it be plumbing, plastering or carpet laying - use an expert.... They do it all the time.

Proseal is the very spawn of Beelzebub and should be avoided at all costs.

It is a tiny part of the cost of your build and will save weeks of heartache.
 
Built two 12's, bought two pre built tanks...
Just saying :D

So...Does that mean you've never built one? If not then how can you compare? I've built quite a few riveted/prosealed fuel tanks. It's not that bad. It's not the sweetest smell in the world.
 
No Mel,

Not saying it is impossible, just time consuming, messy and unnecessary when people with great talent and patience do them for you.

Currently building a 10 and farming the tanks out to a super competent chap who has built many.

We may build homebuilt aeroplanes, but there are areas like this that I bow down to more talented folks and support the micro economy.

Like harnesses, like paint, like upholstery etc etc.
 
Whilst I await my Emp & Wing kits to ship I am getting ready to order the Fuse kit, but can't decide whether to also order the pre-made fuel tank or just build it myself.

For those that have gone before - if you done it over would you build it again yourself, or go with the $600 pre-built option? And how much time would this save?

Reading a few threads I know it looks like one of the messier jobs on the build but my main concern is having to chase around finding & fixing leaks, but again i'm not sure how much of a problem this is in reality?

Thanks!
Paul

I found the leak testing more of a PIA than the actual construction of the tank. There are SO many threads about leaky tanks it was a real worry for me. The tank would really be difficult to remove once the plane is done if any leaks needed to be fixed. If i had to do it again I’d get the prefab tank just for the peace of mind.
 
Built the original square tank. Opened it up to install Van’s upgrades. Opened it up again and enlarged it to take more fuel. Like everything else just work carefully and take your time. Proseal can be messy to work with but it’s not that bad. On the other hand Vans price for a prefabricated tank is quite reasonable. Your call...
 
One further note to the op, the tank ships in the finish kit, not the fuselage kit. Finish kit is a much bigger crate. Might give you a bit more thinking time:D
Cheers, DaveH
 
So far, it Sounds like u should buy the prebuilt tanks. And the quick build wings, fuselage, and get an expert to mount the engine. Find someone to make the canopy too cuz that’s a tough one.
 
I built the fuel tanks for my 6A, 7A and 14. Not a very pleasant task but fairly straightforward. For my 12iS, I purchased them pre-made from Vans (and they did indeed come with the finishing kit). It was a good purchase and they did a really, nice job. Having said that, the 12iS tanks use blind-rivets (not solid) so it would be somewhat easier construction. So; save $600 (actually a bit less, as Proseal is not cheap) and learn a new skill or just have them do it. Either way you will be happy.
 
I was concerned about tank leaks, but, although messy, the construction and Pro-Seal process turned out to be very effective. It’s much easier than one might think to build the tank. Just control the mess with frequent glove changes, be sure to keep test batches of the Pro-seal so you know when it has set and cover your work surface with plastic sheets.
 
One further note to the op, the tank ships in the finish kit, not the fuselage kit. Finish kit is a much bigger crate. Might give you a bit more thinking time:D
Cheers, DaveH

If you're building an iS fuselage, the tank parts are shipped with the fuselage kit and assembled in Section 26iS/U.
 
My error on the prefab fuel tank shipping. I received both fuselage and finishing kits around the same time but was part of the iS fuselage kit. Sorry for senior moment and misinformation.
 
Thanks all for the comments - I've decided to go with the pre-fab tank just for peace of mind.

I have plenty(lots) of other skills to learn anyway during the build, so don't think I'll miss having one less thing to think about.

Cheers,
Paul
 
My original homebuilt tank began leaking a few years ago. I ultimately purchased Van's factory built. Three years later, it developed a leak at a screw in the access panel. It was resealed, and intact so far. I am told that all tanks are prone to vibration stress that may cause weeping at joints/screws eventually.
 
8 1/2 years and just shy of 1000 hours with no leaks on mine that was assembled as part of the kit as opposed to completed at Vans.

Now I have jinxed myself for sure!😱
 
Price increase

Seems like most have sided with purchasing the prefabricated fuel tank, but with the recent price increase it’s now $1200 (double what it cost before). Does that change the equation for anyone?

If the prefab tank is shipped with the finishing kit, can you hold off on the fuel tank decision and just buy it with the finishing kit? (I hate to spend $1200 now on something that can be purchased later.)
 
Honestly if these tanks which I’m building and not having fun do leak, I’ll probably buy the pre-built ones.

I’m giving it the college try but I will only go so far.
 
Interesting that this topic has resurfaced. I was just wondering how truly complete the final fuel tank is now from van’s. Hopefully the price increase goes along with an even more completely finished tank assembly. Anyone know for sure?
 
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Something to consider is the wait time for all the prefab kits. I’d rather work on these annoying tanks for 4 months than have nothing to do.
 
Build tanks? Why not?

I just got back from a vacation in Hawaii. It all really boils down to are you going to fly first class or coach.
You got money and no time. Then the answer is easy.
If you want to go to school and have some fun and a new experience then build the tanks.
I like flying first class, But, Yes I have built a couple sets of tanks, Cause I like the experience and I thought it was kinda fun. And I will build the next sets also.
Another three cents worth Art
 
When I built my tanks I never thought they would pass the leak test, but they never leaked. It’s messy, but not difficult to get them right. It’s certainly not the most complex step in building the plane.

My friend is a retired F-4 pilot. He told me the F-4 tanks always had leaks around screws, and the answer was to pull the screw, shoot in some goo and put the screw back. He said the joke among aircrews was how much useable fuel they really had after years of shooting goo into the tanks.
 
I wasn't able (with mP1020079.jpegy poor skills...) to tighten the ' 12 tank enough. After several messy attempts I decided to have it built. For I'm living in Europe and having to deal with customs en taxes and so on, I chose to have it build by a local aluminum-specialist. I just took the original tank, and he copied it in thicker material (some 0.8mm) to be able to weld it. Fits like a
jigsaw puzzle, and costs around EUR 350. I replaced the anemometer to a lid on top of the tank. The lid is big enough for a men's hand, to be able to clean and feel around. Weigh was slightly higher than the original, but leakfree utill now: 150 hours and counting (total weight 333 KG).
 
Wonder if the welded tank had the same baffle’s in it. That along with the added weight would seam to be problem for a poly tank also. I built a riveted tank with Van’s parts and added a access cover above the small baffle area above the fuel strainer big enough to get your hand through if needed. Has worked great for at least 150 so far.
 
Wonder if the welded tank had the same baffle’s in it.
I hope so because it is a very important feature.
The revised location for the fuel level sensor is a problem as well. Because of the sloped shape of the tank bottom, the gauge probably reads zero when there is about 2 gallons remaining.

Newer members of the RV community probably wouldn't know, but the original RV-12 prototype had a welded aluminum fuel tank. It worked fine, but was slightly heavier and would have been much more expensive than providing rivet together parts that they builder can invest personal labor time into.
 
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Curious - Why isn’t a polyethylene tank available? Sonex uses them.
They have been used in a number of other different aircraft (Kitfox, Avid, and Rans come to mind) and some of those have had leak issues after some time in service.

A couple of negatives for the RV-12 is that they are heavier, more expensive to produce (There is a huge start-up cost involved with making the production mold for a custom shape), and the difficulty of incorporating special internal features like the baffles that are inside of the RV-12 tank that assure a quantity of fuel is retained at the fuel pick-up point regardless of flight attitude.
 
A little late to the party here.... My friend has legacy RV-12 built by Synergy, so obviously professionally built??? Fuel tank developed leak around fuel sender access panel after a few years of flying. For what its worth....
 
As this thread has resurfaced nearly 4 years after I posed the original question, I can report back that I did go with the factory-built tank option, It was a super tidy and neat assembly, and zero leaks after 150+ hrs of flying. I would certainly go down the same path if I were to build again.
 
For those building now, the choice is a lot easier. With the latest changes, the factory built fuel tanks are no longer an option.

Screenshot 2024-02-20 at 1.29.25 PM.png
 
To me building the tank is part of the adventure. Not hard to do. Did it over 6 sessions. Had a few leaks but easy to find by blowing the glove up and spraying with soapy water.
If it leaks in the future I’ve had practice at finding and fixing.
 
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