Bill, how did you determine the initial "one gallon"? The only item I can think of that actually has a mark for one gallon is a portable Blitz-type fuel can and I would not trust they are accurate. Just curious.
Here is how I calibrated my tanks:
1. Saved four of opaque milk jugs. Some jugs are white and were not used, only the semi-transparent jugs were used for my test.
2. Using a Pyrex measuring cup, each of the four jugs were filled with 16 cups of water and marked with a blue Sharpie brand marker.
3. The jugs were emptied and allowed to dry for two weeks prior to use. (I would hate one of the Forum members to post that I might have introduced water into my fuel system.)
4. One tank at a time, starting with the right tank, the quick drain was removed and the fuel was drained into five gallon gas cans. A large red funnel, complete with a micro screen in the bottom, was used to keep from spilling and to catch anything that might have come lose.
5. With the quick drains removed, I lifted the tail into the level flight attitude to see if any more fuel would come out. Maybe a thimble?s worth spilled out.
6. The quick drains were reinstalled and torqued.
7. With the aircraft still in the flight position, the Dynon SkyView was put in the calibration mode.
8. Starting on the left tank, the SkyView asked for two gallons of fuel be added.
9. I poured 100LL from my five gallon gas cans, utilizing the above mentioned red funnel-filter, into two previously scientifically calibrated milk jugs.
10. The filter was then placed in the tank replenishment orifice and two gallons of 100LL from the previously mentioned milk jugs was then dispensed into thank via the red fluid deflection and filtering device.
11. The Dynon SkyView then asked for confirmation that fuel, was in fact added. At which time the appropriate button was pressed, a note was made on some type of white parchment, probably derived from some formerly hard plant matter.
12. The above steps were repeated nine times, until the designer?s 18 gallon specification was achieved.
13. Upon completion of the task, an additional 1.5 gallons of dead blue dinosaurs was dispensed into the tank, prior to lowing the tail.
14. The above procedures were repeated for the second AKA, right, tank.
Come on guys, you are over thinking this.