Repairing a Aluminum Aux Fuel Cell

Bill/KB - let me know if going too far astray with posts like this, OK?026-03-18 Aux Tank Repair

The cap was increasingly difficult to remove when ambient temperatures were up.

And, something is intermittently clogging fuel flow to the pump or the pump is going bad.

JEGS part number  547-350-201-06.

JAZZ part number 350-201-06.



This is a newer and better flange than sold previously, which was a stamped steel unit.

This one is machined aluminum, which might prevent the cap removal problem when hot by eliminating
different thermal coefficients of expansion 
between the aluminum tank and steel flange.

As KB would say the three 'F's....
 

Had to enlarge tank 'hole' to allow the new flange to fit.
After that, modified the flange to not interfere fit against the welding.
 

 The hardest part was removing/installing the foam.
A true PITA.

Oh, also forgot how hard it is to put the nylon washer and nut onto bolt from inside the tank. Big fat arthritic hands and all that..
 

After mechanical work, polished and ready for leak test then installation.