Setting up a gas tank
Tutorials > Setting up a gas tank
| Plan | Components | Bottle | Lines | Install | Connect | Three line system |
An airplane with a two-stroke gasoline engine requires a fuel tank, a way to get the fuel to the carburetor, a method of filling the tank and a way to vent it. There are different ways to do it; this tutorial describes an approach has worked well for me - a two line system based on a Fiji water bottle.
Photos were taken from two different setups so two different bottle sizes will appear - 500 mL for a 50cc engine, and 330 mL for a 20cc engine.
Plan the system
It's essential to plan the system beforehand to determine what parts and supplies you'll need and the placement of the tanks and lines.
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Here's a look at a fuel system ready for installation.
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Assemble the components
Time to get all the stuff together!
Everything starts with the bottle. Fiji bottles are light, strong and square and are available in varying sizes - 360 mL, 500 mL and 1L.
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This cap from PSP Manufacturing is a perfect fit for Fiji bottles and features outer and inner barbs.
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The single barb vent, also from PSP Manufacturing, is ideal for connecting the vent line.
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My choice of pickup is the Walbro felt clunk.
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For extra insurance I put a fuel filter in between the tee and the carburetor.
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This fuel dot is made by McFueler.
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I use this part from Hangar 9 as a vent line fitting.
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A package of fuel tees - only one is required.
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Tygon tubing for everything outside of the tank.
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Viton tubing for the in-tank line.
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An assortment of zip ties; I use a small size.
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The tank should sit on foam.
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Velcro is a good way to secure the tank.
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Prepare the bottle
Start by testing the cap - I came across a bottle that the cap would not thread onto.
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Drill the vent hole - make sure the location suits the planned installation. I use a brad point drill bit because the spurs scribe a nice clean hole; I turn it with my fingers for better control.
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A nice clean hole.
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Time to install the barb. Start by dropping it into the bottle.
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A piece of wire helps guide it into position.
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There's an internal keyway for a hex driver - insert that...
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...then hold onto it while tightening the nut with a wrench.
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Barb installed.
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Configure the lines
Take a minute to determine the required length of the lines for the clunk, carb, vent and fill. Be generous - better too long than too short!
Here's a carburetor line.
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And here a vent line is marked.
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Attach the felt clunk to the Viton line and inner cap barb.
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Install the cap and ensure that the clunk reaches as far as possible without catching on the inside of the bottle.
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Attach the vent line to the barb.
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Build the supply ine to the carb, incorporating the tee for the fill line and the filter. Note the missing zip tie on the tee side of the filter - that was installed after the photo was taken.
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The fuel system, ready to install.
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Install the tank
Installing the tank is a quick job. Be sure to route the vent line down and along the side of the tank - this prevents gas from leaking out of the vent line during flight.
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Connect the system
The final piece of the puzzle - making the connections.
Connect the carburetor supply line.
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Don't forget the zip tie!
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Route the vent line and connect it to the fitting.
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Connect the fill line to the tee and route it out of the fuel dot housing.
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Connect the fuel dot.
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Installation complete.Three line system
Since I started flying gas airplanes in 2012 I've used a two-line gas system. I use a filter in the gas can, a felt fuel clunk in the gas tank, and an in-line filter in the supply line to the carburetor. It was recently pointed out to me that this might not be the best approach; consider the following diagram:
The blue arrows indicate five additional points for potential air leaks. A three line system requires neither the T-fitting nor the inline filter (pumping gas into the tank through the felt clunk negates its effect as a filter, which is why I add a separate one in the supply line). I've switched to 3-line setups.
