Sonex Waiex B, part 25, will I completely destroy a 500 dollar fuel tank

I install a Stainless Steel washer and nut into the fuel tank so the fuel level prop is removable.
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[@markjgaunt]

That was well done Andy , hope all the swarff from the nylon drill holes washed out ok

[@pandyseven]

Absolutely

[@pandyseven]

yes the cleaning took a while but I got it all out, that was my biggest nightmare.

[@johnjensen2217]

Nicely done and a very clever design for the internal retainer. I really appreciate the detailed videos. Do you anticipate ever having to remove that fuel sender after the build is complete? Can the fuel tank be dropped out from under the glareshield for maintenance?

[@pandyseven]

Hi John, I hope I never have to replace the sender , but as anything if the provision is there you may as well have the ability to remove/replace. my objective in doing the sender this was was I wanted it fixed tight into a stainless nut, rather than just screwing into the poly tank or tapping it with a thread. The glare shield and tank straps are build together as one unit, and the tank is put in afterward, therefore one would assume the tank is removable. The way I am doing my tank is I have a small section of fuel line from the firewall back to the tank that is done with flares, so if that is unscrewed the tank then is technically removeable, without destroying any fittings that I use Teflon paste and Loctite on.

[@dan_der_flieger]

Ingenious! Nice job Andy! Ive been wondering about the fuel tank inserts and this answered most of my questions.
The semi-circle retaining clips with the welded bolts - did you make that yourself or did it come with the fuel level sender?

[@pandyseven]

Hi Dan, I spent about a week sketching an idea on paper until I worked that design out. My guys at the metal workshop made it for me, and believe it worked fantastic. I am thinking of doing something similar for the rudder peddles.

[@dan_der_flieger]

@@pandyseven Some of those machinists have incredible workmanship. Looks like your part came out perfect to me. Can't wait to see what you have in store for the rudder peddles.

[@bryancotton7279]

@@pandyseven Why do you need something like that for the rudder pedals? Clever way to mount your sender. I went the route of marking the tank, and having a light/camera/display so I can visually check the fuel level.

[@pandyseven]

Hi Bryan,
I am not changing the rudder pedals just toying with an idea to make them look good. Just to step the Sonex up to the next level...