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Step 1: Temporarily bolt the Fuel Tank to the Center Section Assembly and the F -1207J Attach Angle using the hardware call-outs in Figure 1.

Step 2: Center the Filler Neck Assembly on the skin fuel opening as shown in Figure 1. For the best fit of the Filler Neck Assembly (betweenthe Fuel Tank Assembly and the F- 1277-R Fwd Turtle Deck Skin) it may be necessary to adjust the length by loosening the hose clamps andextending or shortening the assembly. Bend the upper flange of the T-1211 Fuel Neck as required for a best fit against the fwd turtle deck skin(small gaps can be filled with fuel tank sealant).

Step 3: Once satisfied with the position of the Filler Neck As sembly, match-drill #30 the holes in the F-1277-R Fwd Turtle Deck Skininto the flange of the T-1211 Fuel Neck, cleco as you go. Trace a circle onto the T-1204A Top Tank Skin around the edge of theT-1204B Flange. Remove and disassemble the Filler Neck Assembly. Remove the fuel tank from the fuselage.

Step 4: Position the T-1204B Flange on the T-1204A Top Tank Skin, centered in the circle from Step 3. Match-drill #30

the holes in the flange into the top tank skin, cleco as you go. Trace a circle onto the T-1204A Top Tank Skin aroundthe inside of the flange. Mark the r otational position of the flange. Remove the flange and the top tank skin.

Step 5: Remove the material, marked with the inner circle from Step 4, from the T-1204A Top Tank Skin.This can be done by drilling a 3/4 inch hole roughly centered in the inner circle. Usemetal cutting snips to make a rough cut to within 1/8 inch of the inner circle mark, thenuse metal cutting snips to make a finish cut to the inner circle mark. Finish the hole

with a file. Deburr the top tank skin and the T-1211 Fuel Neck. Prime the outside ofthe fuel neck and T-1204B Flange only! Remove the rag and drill chips from insidethe tank. Check to be thoroughly sure that no chips or constructiondebris remain in the tank.

Step 6: Fabricate two T-1216 Clips per Figure 2.

NOTE: Cleco the T-1204A Top Tank Skin to the fuel tank for reference.

Step 7: Fabricate the T-1215 Fuel Return Line using a 34 1/4 inch length ofAT0-032X1/4 soft aluminum tube. Install a nut and sleeve on one end of the fuelreturn line and flare that end. From the bulkhead fitting, route the fuel return line up

to the T-1204A T op Tank Skin, then aft (near the rivet holes for the T-1216 Clips),then the remainder up through the fuel tank opening. Capture the fuel return linewith the clips and rivet the clips to the top tank skin per call-out in Figure 1.

Step 8: Rivet the T -1204A Top Tank Skin to the Fuel Tank Assembly per thecall-out in Figure 1. Rivet the T-120 4B Flange to the top of the Fuel Tank

Assembly. Install the T-1215 Fuel return line to the AN832-4D bulkhead fitting.

Step 9: Add sealant in any remaining areas, corners cracks and crannies asnecessary. Install the T-1209 Res Sender Plate and IE F-385B Sending Unit with

sealant using the hardware called out on Page 37-04, Figure 3. Use 1/16 inch thicklayer of sealant between the res sender plate and the T-1202 Fwd Tank Bulkheadand in place of the IE F-385 Gasket. Tighten screws just enough to cause sealant

to bulge evenly fr om underneath the perimeter of the sender plate.

AN4-4ANAS1149F

F-1207J

FILLER NECK ASSEMBLY(SHOWN TRANSPARENT)

SKIN FUEL OPENING

FUEL TANK OPENING

F-1277-R

T-1204A

T-1211

T-1204B

AD-41H,TYP.

T-1215

T-1216,

2 PLACES

9/321/32

1/21 7/32

FIGURE 2: T-1216 FABRICATION

DRILL #30

T-1215

AN819-4D

AN818-4D

AN832-4D

C

ENTERSECTIONASSEMBLY

FIGURE 1: FITTING THE FUEL TANK

AN3-7ANAS1149F0332P

FUEL TANK ASSEMBLY

2X

AD-41H,

TYP.

PAGE REVISION: DATE:

VAN'S AIRCRAFT, INC.

02/22/10PAGE 37-06 RV-12 REVISION: 1 DATE: