ECHANICAL FAST FILL U Dave McDonald simple effective fast-fill device will work suction-feed fuel system some very minor modifications will work pressure system lineage design unknown Bob Whitney provided filler very similar further modifications have produced version seen filler systems used Gb-Bee clamp ring top portion Cox 049 cylinder design similar appearance dimensionally different dimensions what used particular application may wish change dimensions suit particular needs am currently working slightly smaller design Scale Racing application filler may appear difficult build first always difficult second third etc should able build hour Simple machining required manufacture design filler made almost entirely using small lathe Only part requires some mill work may accomplished using drill press mill vise filler made 6061T6 aluminum 360 brass Reasons material selection ease machining ready availability suspect DelrinTM plunger could substituted brass plunger thereby saving small amount weight will need spring make final filler work provide positive seal required prototype used spring 041 wire giving 777 pounds maximum load spring rate 2824 current fillers using 035 wire giving five-pound maximum load spring rate 1608 will need tap die set allow filler easily removed maintained filler using 1/2.32 thread material well tap die available MSC Industrial Supply Company see list Machining Before start making parts make fixture resembles solder collar print 3/4 hex material 350 long will want tap hex material /232 After tapping cut vertical slot through wall threaded area will use fixture clamp during milling operation counterboring filler body slot will keep filler body spinning during milling operation Make solder collar first have used brass permits easy soldering tank Using piece 750 58 Model Aviation mbled fast-fill small lightweight Aluminum 6061 T6 Very few parts worry about Only simple machining required brass turn diameter down 700 turn inset portion collar portion goes tank down 525 diameter 100 long Bore 468 diameter hole through center Tap hole 1/232 Leave 030 flange top portion collar cut part off will now have nice brass flange provides good solder base tank internal threads screw Next brass seal plunger made using 1/2 diameter stock keeping amount material needing turned minimum Turn diameter down 332 x 453 long 332 dimension fairly critical have small contact area between plunger filler body tight tolerance keeps parts having too much clearance hindering performance Turn bottom part down 250 x 045 long provides area 0-ring seat Leave 090 flange top part use cutoff tool remove part Turn part around reinsert lathe counterbore inside 250 diameter 498 deep Drill tap remaining bottom area 2-56 2-56 used hold 0-ring 0-ring washer place now ready drill four transfer holes allow fuel tank Locate area 395 top flange will center cross holes Drill two holes 900 apart filler body next Using aluminum part actually going make something resembles old Gb-Bee clamp ring Using piece 5/ bar stock turn area down 495 diameter 140 long worry cannot get threads up shoulder area will undercut shoulder area dimension 462 x 050 makes Photos author Steve Kaluf Graphic Design Jill Ann Gavanaugh Figure 2 015 Deep Slot Milled Vent Fuel Pressure System Omitted Suction Only Model II II ISeal Plunger II II 0 Mechanical Fast Fill Drawn Al Stone Filler Body Solder Collar Seal Plunger 450 Diameter x 110 625Deep C-Bore 333 Note Undercut Flange Acceptable 00751/2 x 32 Thread 0-Ring Backup Washer 0125 0260 0110 /7 120 x 03 Filler Body 1 Required Material 6061 Aluminum 1I232 Thread Through F--030 Solder Collar 1 Required Material Brass Break Sharp Corners #44 Drill Through 342 0031 0-Ring Backup Washer 1 Required Material 6061 Aluminum 090 Break Sharp Corners 500 250 Counterbore 395 Seal Plunger 1 Required Material Brass Drill /a inch Through 2 900 Apart Remove Burrs L 332] 25Qj 2-56 Tap Through 498 August 1999 59 Figure 1 1/232 Threads Cut Slot Using Dremel Saw Bun 256 Screw Introducing Series III 30 Wingsp Laser Cut Rubber Powered Flying MQdels Kit #307 Over 110 LASER CUT PARTS Kit #308 Over 90 LASER CUT PARTS Kit #309 Over 110 LASER CUT PARTS expanding line airplanes addition Series III 30 wingspan laser cut kits Like walnut series line geared toward exciting subject matter captures best model aviation has offer Besides offering cleanest laser cuts comprehensive plans free flight kit provide following quality features Hand Selected Balsa Color Peel & Stick Decal Set 9 Plastic Propeller Full Size Plan FAI Thn II Rubber Step Step Instructions Vacuum Molded Parts Light Weight Colored Tissue Call today 1-800-458-2828 Ext 800 ask information packet Dumas line Rubber Powered Flying Models dumas aircraft DUMAS PRODUCTS INC 909AMA E 17th St Tucson AZ 85719 Phone 520-623-3742 Fax 520-620-1329 wwwdumasproductscom sure body will seal against top solder collar After threads filler body bore bole 333 through center dimension critical maintain good fit between plunger body permits plunger work smoothly body After hole bored through part chamfer hole dimension critical trying to make sure 0-ring seals properly body Leave 120 flange cut part off will now use fixture made beginning screw body Place lathe counterbore top dimension 450 x 110 deep now ready remove fixture part Set aside milling slots used tighten body collar last part lathe 0ring backup washer simply part 342 diameter 031 thick #44 drill hole center used hold 0-ring plunger using 2-56 screw Use I/g end mill make two slots 075 deep across filler body slots permit use Cox wrench tighten body solder collar Final Assembly After making sure parts have no burrs ready assemble filler valve Remove 100 end spring Slide spring over plunger insert filler body Place 0-ring end plunger take 2-56 screw washer screw bottom plunger As work plunger will note transfer holes open below filler body permitting fuel transfer allow plunger return closed position note 0-ring seals against bottom filler body Make sure 2-56 screw tight finished Installation Solder brass collar tank Take care get solder top flange could cause filler body seal properly Screw filler body collar tighten Cox wrench overtighten want make sure snug things will need check over time tightness 2-56 screw condition 0-ring tightness body collar Pressure Modification running pressure fuel system will want modify plunger slightly Use /s smaller end mill make vertical slots transfer holes Fig 2 suggest mill approximately 015 deep will still provide ample wall thickness provide avenue tank vent filling have questions would like filler cannot build just let know will happy assist questions obtaining filler Thanks Al Stone doing drawings project McDonald Box 384 Daleville IN 47334 DMcD143@aolcom Material 3/ 5/ aluminum bar stock 1/2 3/4 brass bar stock 420 OD compression spring 035 dia wire Y2-inch long 1/4 x 3/ x 1/16 Buna N 0-ring 2-56 x 1/4 screw material may obtained MSC Industrial Supply Company Tel 800 645-7270 191 1 IIlIlid [1 ntiques Military Civilian Helicopters Sailplanes have worlds largest aircraft documentation colledion 7400 different full color photo studies 1903-1 350003-view line drawings Z 1999 Catalog/Guide 228 pages M$1000 Only $8 $1 5 00 Bob Bankae&a $1800 AIRCRAFT DOCUMENTATION 3114 Yukon Avenue a Mesa CA 92626 714 979-8058 htta//wwwimtnet/ims/sealehtml 60 Model Aviation
Edition: Model Aviation - 1999/08
Page Numbers: 58, 59, 60
Edition: Model Aviation - 1999/08
Page Numbers: 58, 59, 60
ECHANICAL FAST FILL U Dave McDonald simple effective fast-fill device will work suction-feed fuel system some very minor modifications will work pressure system lineage design unknown Bob Whitney provided filler very similar further modifications have produced version seen filler systems used Gb-Bee clamp ring top portion Cox 049 cylinder design similar appearance dimensionally different dimensions what used particular application may wish change dimensions suit particular needs am currently working slightly smaller design Scale Racing application filler may appear difficult build first always difficult second third etc should able build hour Simple machining required manufacture design filler made almost entirely using small lathe Only part requires some mill work may accomplished using drill press mill vise filler made 6061T6 aluminum 360 brass Reasons material selection ease machining ready availability suspect DelrinTM plunger could substituted brass plunger thereby saving small amount weight will need spring make final filler work provide positive seal required prototype used spring 041 wire giving 777 pounds maximum load spring rate 2824 current fillers using 035 wire giving five-pound maximum load spring rate 1608 will need tap die set allow filler easily removed maintained filler using 1/2.32 thread material well tap die available MSC Industrial Supply Company see list Machining Before start making parts make fixture resembles solder collar print 3/4 hex material 350 long will want tap hex material /232 After tapping cut vertical slot through wall threaded area will use fixture clamp during milling operation counterboring filler body slot will keep filler body spinning during milling operation Make solder collar first have used brass permits easy soldering tank Using piece 750 58 Model Aviation mbled fast-fill small lightweight Aluminum 6061 T6 Very few parts worry about Only simple machining required brass turn diameter down 700 turn inset portion collar portion goes tank down 525 diameter 100 long Bore 468 diameter hole through center Tap hole 1/232 Leave 030 flange top portion collar cut part off will now have nice brass flange provides good solder base tank internal threads screw Next brass seal plunger made using 1/2 diameter stock keeping amount material needing turned minimum Turn diameter down 332 x 453 long 332 dimension fairly critical have small contact area between plunger filler body tight tolerance keeps parts having too much clearance hindering performance Turn bottom part down 250 x 045 long provides area 0-ring seat Leave 090 flange top part use cutoff tool remove part Turn part around reinsert lathe counterbore inside 250 diameter 498 deep Drill tap remaining bottom area 2-56 2-56 used hold 0-ring 0-ring washer place now ready drill four transfer holes allow fuel tank Locate area 395 top flange will center cross holes Drill two holes 900 apart filler body next Using aluminum part actually going make something resembles old Gb-Bee clamp ring Using piece 5/ bar stock turn area down 495 diameter 140 long worry cannot get threads up shoulder area will undercut shoulder area dimension 462 x 050 makes Photos author Steve Kaluf Graphic Design Jill Ann Gavanaugh Figure 2 015 Deep Slot Milled Vent Fuel Pressure System Omitted Suction Only Model II II ISeal Plunger II II 0 Mechanical Fast Fill Drawn Al Stone Filler Body Solder Collar Seal Plunger 450 Diameter x 110 625Deep C-Bore 333 Note Undercut Flange Acceptable 00751/2 x 32 Thread 0-Ring Backup Washer 0125 0260 0110 /7 120 x 03 Filler Body 1 Required Material 6061 Aluminum 1I232 Thread Through F--030 Solder Collar 1 Required Material Brass Break Sharp Corners #44 Drill Through 342 0031 0-Ring Backup Washer 1 Required Material 6061 Aluminum 090 Break Sharp Corners 500 250 Counterbore 395 Seal Plunger 1 Required Material Brass Drill /a inch Through 2 900 Apart Remove Burrs L 332] 25Qj 2-56 Tap Through 498 August 1999 59 Figure 1 1/232 Threads Cut Slot Using Dremel Saw Bun 256 Screw Introducing Series III 30 Wingsp Laser Cut Rubber Powered Flying MQdels Kit #307 Over 110 LASER CUT PARTS Kit #308 Over 90 LASER CUT PARTS Kit #309 Over 110 LASER CUT PARTS expanding line airplanes addition Series III 30 wingspan laser cut kits Like walnut series line geared toward exciting subject matter captures best model aviation has offer Besides offering cleanest laser cuts comprehensive plans free flight kit provide following quality features Hand Selected Balsa Color Peel & Stick Decal Set 9 Plastic Propeller Full Size Plan FAI Thn II Rubber Step Step Instructions Vacuum Molded Parts Light Weight Colored Tissue Call today 1-800-458-2828 Ext 800 ask information packet Dumas line Rubber Powered Flying Models dumas aircraft DUMAS PRODUCTS INC 909AMA E 17th St Tucson AZ 85719 Phone 520-623-3742 Fax 520-620-1329 wwwdumasproductscom sure body will seal against top solder collar After threads filler body bore bole 333 through center dimension critical maintain good fit between plunger body permits plunger work smoothly body After hole bored through part chamfer hole dimension critical trying to make sure 0-ring seals properly body Leave 120 flange cut part off will now use fixture made beginning screw body Place lathe counterbore top dimension 450 x 110 deep now ready remove fixture part Set aside milling slots used tighten body collar last part lathe 0ring backup washer simply part 342 diameter 031 thick #44 drill hole center used hold 0-ring plunger using 2-56 screw Use I/g end mill make two slots 075 deep across filler body slots permit use Cox wrench tighten body solder collar Final Assembly After making sure parts have no burrs ready assemble filler valve Remove 100 end spring Slide spring over plunger insert filler body Place 0-ring end plunger take 2-56 screw washer screw bottom plunger As work plunger will note transfer holes open below filler body permitting fuel transfer allow plunger return closed position note 0-ring seals against bottom filler body Make sure 2-56 screw tight finished Installation Solder brass collar tank Take care get solder top flange could cause filler body seal properly Screw filler body collar tighten Cox wrench overtighten want make sure snug things will need check over time tightness 2-56 screw condition 0-ring tightness body collar Pressure Modification running pressure fuel system will want modify plunger slightly Use /s smaller end mill make vertical slots transfer holes Fig 2 suggest mill approximately 015 deep will still provide ample wall thickness provide avenue tank vent filling have questions would like filler cannot build just let know will happy assist questions obtaining filler Thanks Al Stone doing drawings project McDonald Box 384 Daleville IN 47334 DMcD143@aolcom Material 3/ 5/ aluminum bar stock 1/2 3/4 brass bar stock 420 OD compression spring 035 dia wire Y2-inch long 1/4 x 3/ x 1/16 Buna N 0-ring 2-56 x 1/4 screw material may obtained MSC Industrial Supply Company Tel 800 645-7270 191 1 IIlIlid [1 ntiques Military Civilian Helicopters Sailplanes have worlds largest aircraft documentation colledion 7400 different full color photo studies 1903-1 350003-view line drawings Z 1999 Catalog/Guide 228 pages M$1000 Only $8 $1 5 00 Bob Bankae&a $1800 AIRCRAFT DOCUMENTATION 3114 Yukon Avenue a Mesa CA 92626 714 979-8058 htta//wwwimtnet/ims/sealehtml 60 Model Aviation
Edition: Model Aviation - 1999/08
Page Numbers: 58, 59, 60
ECHANICAL FAST FILL U Dave McDonald simple effective fast-fill device will work suction-feed fuel system some very minor modifications will work pressure system lineage design unknown Bob Whitney provided filler very similar further modifications have produced version seen filler systems used Gb-Bee clamp ring top portion Cox 049 cylinder design similar appearance dimensionally different dimensions what used particular application may wish change dimensions suit particular needs am currently working slightly smaller design Scale Racing application filler may appear difficult build first always difficult second third etc should able build hour Simple machining required manufacture design filler made almost entirely using small lathe Only part requires some mill work may accomplished using drill press mill vise filler made 6061T6 aluminum 360 brass Reasons material selection ease machining ready availability suspect DelrinTM plunger could substituted brass plunger thereby saving small amount weight will need spring make final filler work provide positive seal required prototype used spring 041 wire giving 777 pounds maximum load spring rate 2824 current fillers using 035 wire giving five-pound maximum load spring rate 1608 will need tap die set allow filler easily removed maintained filler using 1/2.32 thread material well tap die available MSC Industrial Supply Company see list Machining Before start making parts make fixture resembles solder collar print 3/4 hex material 350 long will want tap hex material /232 After tapping cut vertical slot through wall threaded area will use fixture clamp during milling operation counterboring filler body slot will keep filler body spinning during milling operation Make solder collar first have used brass permits easy soldering tank Using piece 750 58 Model Aviation mbled fast-fill small lightweight Aluminum 6061 T6 Very few parts worry about Only simple machining required brass turn diameter down 700 turn inset portion collar portion goes tank down 525 diameter 100 long Bore 468 diameter hole through center Tap hole 1/232 Leave 030 flange top portion collar cut part off will now have nice brass flange provides good solder base tank internal threads screw Next brass seal plunger made using 1/2 diameter stock keeping amount material needing turned minimum Turn diameter down 332 x 453 long 332 dimension fairly critical have small contact area between plunger filler body tight tolerance keeps parts having too much clearance hindering performance Turn bottom part down 250 x 045 long provides area 0-ring seat Leave 090 flange top part use cutoff tool remove part Turn part around reinsert lathe counterbore inside 250 diameter 498 deep Drill tap remaining bottom area 2-56 2-56 used hold 0-ring 0-ring washer place now ready drill four transfer holes allow fuel tank Locate area 395 top flange will center cross holes Drill two holes 900 apart filler body next Using aluminum part actually going make something resembles old Gb-Bee clamp ring Using piece 5/ bar stock turn area down 495 diameter 140 long worry cannot get threads up shoulder area will undercut shoulder area dimension 462 x 050 makes Photos author Steve Kaluf Graphic Design Jill Ann Gavanaugh Figure 2 015 Deep Slot Milled Vent Fuel Pressure System Omitted Suction Only Model II II ISeal Plunger II II 0 Mechanical Fast Fill Drawn Al Stone Filler Body Solder Collar Seal Plunger 450 Diameter x 110 625Deep C-Bore 333 Note Undercut Flange Acceptable 00751/2 x 32 Thread 0-Ring Backup Washer 0125 0260 0110 /7 120 x 03 Filler Body 1 Required Material 6061 Aluminum 1I232 Thread Through F--030 Solder Collar 1 Required Material Brass Break Sharp Corners #44 Drill Through 342 0031 0-Ring Backup Washer 1 Required Material 6061 Aluminum 090 Break Sharp Corners 500 250 Counterbore 395 Seal Plunger 1 Required Material Brass Drill /a inch Through 2 900 Apart Remove Burrs L 332] 25Qj 2-56 Tap Through 498 August 1999 59 Figure 1 1/232 Threads Cut Slot Using Dremel Saw Bun 256 Screw Introducing Series III 30 Wingsp Laser Cut Rubber Powered Flying MQdels Kit #307 Over 110 LASER CUT PARTS Kit #308 Over 90 LASER CUT PARTS Kit #309 Over 110 LASER CUT PARTS expanding line airplanes addition Series III 30 wingspan laser cut kits Like walnut series line geared toward exciting subject matter captures best model aviation has offer Besides offering cleanest laser cuts comprehensive plans free flight kit provide following quality features Hand Selected Balsa Color Peel & Stick Decal Set 9 Plastic Propeller Full Size Plan FAI Thn II Rubber Step Step Instructions Vacuum Molded Parts Light Weight Colored Tissue Call today 1-800-458-2828 Ext 800 ask information packet Dumas line Rubber Powered Flying Models dumas aircraft DUMAS PRODUCTS INC 909AMA E 17th St Tucson AZ 85719 Phone 520-623-3742 Fax 520-620-1329 wwwdumasproductscom sure body will seal against top solder collar After threads filler body bore bole 333 through center dimension critical maintain good fit between plunger body permits plunger work smoothly body After hole bored through part chamfer hole dimension critical trying to make sure 0-ring seals properly body Leave 120 flange cut part off will now use fixture made beginning screw body Place lathe counterbore top dimension 450 x 110 deep now ready remove fixture part Set aside milling slots used tighten body collar last part lathe 0ring backup washer simply part 342 diameter 031 thick #44 drill hole center used hold 0-ring plunger using 2-56 screw Use I/g end mill make two slots 075 deep across filler body slots permit use Cox wrench tighten body solder collar Final Assembly After making sure parts have no burrs ready assemble filler valve Remove 100 end spring Slide spring over plunger insert filler body Place 0-ring end plunger take 2-56 screw washer screw bottom plunger As work plunger will note transfer holes open below filler body permitting fuel transfer allow plunger return closed position note 0-ring seals against bottom filler body Make sure 2-56 screw tight finished Installation Solder brass collar tank Take care get solder top flange could cause filler body seal properly Screw filler body collar tighten Cox wrench overtighten want make sure snug things will need check over time tightness 2-56 screw condition 0-ring tightness body collar Pressure Modification running pressure fuel system will want modify plunger slightly Use /s smaller end mill make vertical slots transfer holes Fig 2 suggest mill approximately 015 deep will still provide ample wall thickness provide avenue tank vent filling have questions would like filler cannot build just let know will happy assist questions obtaining filler Thanks Al Stone doing drawings project McDonald Box 384 Daleville IN 47334 DMcD143@aolcom Material 3/ 5/ aluminum bar stock 1/2 3/4 brass bar stock 420 OD compression spring 035 dia wire Y2-inch long 1/4 x 3/ x 1/16 Buna N 0-ring 2-56 x 1/4 screw material may obtained MSC Industrial Supply Company Tel 800 645-7270 191 1 IIlIlid [1 ntiques Military Civilian Helicopters Sailplanes have worlds largest aircraft documentation colledion 7400 different full color photo studies 1903-1 350003-view line drawings Z 1999 Catalog/Guide 228 pages M$1000 Only $8 $1 5 00 Bob Bankae&a $1800 AIRCRAFT DOCUMENTATION 3114 Yukon Avenue a Mesa CA 92626 714 979-8058 htta//wwwimtnet/ims/sealehtml 60 Model Aviation
