7AC Aeronca Fuel Tank

D

Dcsmjs

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Joined
Oct 4, 2025
Messages
10
Location
Princeton Illinois
Disclaimer: I’m not an A&P but I would like to remove my fuel tank ( 13 gallon) original tank, and send it in for a crack repair in the weld by the fuel gauge. I do have some mechanical skills, working on cars etc. Can I do this legally, and how difficult is it. I will have it inspected by an A&P once finished. Any advice welcome.
Dan
 
Legally, probably not. But JB Weld and glass cloth will fix an auto tank right now. If you run alcohol JB says don't use their product.

I suppose I could carefully relay a story from someone who wishes to be anonymous? Fuselage tank made of thin stainless had multiple leaks. Welder "fixed" it for $800. Still leaked. Said anonymous person did the JB Weld trick three years ago, and reports no leaks. He/she says that auto fuel with a bit of ethanol doesn't seem to have caused problems.

Both the FAA and the JB Weld technical staff state that JB Weld will not work as an adhesive or repair material on aircraft. There are approved epoxies, but it is difficult to wade through the technical details, and when you find a suitable approved adhesive it is going to be over $100/oz.
 
Bob Turner said:
Legally, probably not. But JB Weld and glass cloth will fix an auto tank right now. If you run alcohol JB says don't use their product.

I suppose I could carefully relay a story from someone who wishes to be anonymous? Fuselage tank made of thin stainless had multiple leaks. Welder "fixed" it for $800. Still leaked. Said anonymous person did the JB Weld trick three years ago, and reports no leaks. He/she says that auto fuel with a bit of ethanol doesn't seem to have caused problems.

Both the FAA and the JB Weld technical staff state that JB Weld will not work as an adhesive or repair material on aircraft. There are approved epoxies, but it is difficult to wade through the technical details, and when you find a suitable approved adhesive it is going to be over $100/oz.
Click to expand...
Thanks Bob, yeah I think it may be worth a try since the leak is very minute, in fact the only way we found it was the stain around the fuel gauge port weld. There was a fuel smell after top off in the cabin that goes away after burning a few gallons. Do you know if anyone is still making new tanks for Champs?
 
For what it’s worth, the easier and better answer is often “embrace the suck”

The short cut stuff always ends up a much larger pain in the butt later.

If you’re going to keep the plane fix it proper, capt obvious I know ;)

If you’re going to flip it, just discount it and be clear

As a buyer when I see some janky repair, and both me and my IA on pre buy WILL see it, my counter is going to be much much lower than a honestly acknowledged crack, plus now the rest of the plane is suspect, you’re ether going to get a much lower counter or more likely I just get angry my time was not respected and I walk

Maybe it can be properly fixed in place?
 
Thanks JackC, I have come to the same conclusion. I’m going to have it removed and repaired/rebuilt during annual. I found a shop that specializes in this. It’s just money, lol
 
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