Larry Zepp's Blog (9)

Aileron stops for piano hinge option


The aileron stops for the piano hinge aileron option need to be longer than the standard stop shown in the plans. The stops that I received with my piano hinge aileron option were labeled for the PH stop, but they were the standard size and matched the dimensions in the plans for standard stops.


A drawing for the longer piano hinge…


Added by Larry Zepp on September 29, 2013 at 7:43pm — 1 Comment

Making sure the fuel sender is sealed

Hi Builders,

I wanted to make very sure that my fuel senders were sealed before putting the tank in the wing and then filling it with fuel in the future!


The builders guide says the screws should have fiber washers under the head for sealing. These are no longer provided in the supplied VDO install kit. It sounds like a very good idea to have a fiber washer to help seal or a copper washer - like the seal washer used in banjo fuel fittings. I am also using the…


Added by Larry Zepp on June 16, 2013 at 11:13am — 5 Comments

Cleaning the inside of the fuel tanks

After cutting the 59 mm hole for the fuel sender, I needed to get some chips out of the tank.

It worked well to get a small 110 VAC floodlight bulb and socket that would fit into the fuel cap hole to light the inside. To remove chips, taping a painters tack cloth to a long stick made it really easy to pick out random chips and make the tank inside clean and ready to seal the sender.

Larry Zepp - Zodiac 650B builder

Added by Larry Zepp on May 29, 2013 at 10:28am — 2 Comments

Sealants for fuel fittings, fuel cap neck & sender

I am finally working on the rt. tank and fuel system prior to closing the right wing. I did some research on sealants for the stock welded fuel tanks - so I should never have any leakage problems!!

Tapered pipe thread fittings -

I have long experience using either Loctite # 592 - Pipe sealant with Teflon (PST) or Permatex pipe thread sealant on fuels, oils and high pressure gases. Both sealants cure when air is excluded and have teflon in them to prevent galling of metal pipe…


Added by Larry Zepp on April 22, 2013 at 4:09pm — 4 Comments

Aluminum cutter 2.0

Aluminum cutter 2.0 - A dremel tool is probably the most useful tool tol help with your homebuilt project. When trying to use a cutoff wheel, however, you have to control depth, angle and path all at once. Dremel doesn't make a base for the tool like the base on a skilsaw, but that would really help!


Dremel does make an attachment that threads onto…


Added by Larry Zepp on October 27, 2012 at 8:18pm — 1 Comment

Planning your Zodiac wing for a fuel injected engine –

By Larry Zepp, Zodiac 650B builder


When you are building your wing skeleton, you need to plan for a fuel return line to each wing tank if you are planning to use a fuel injected engine. I am planning to use the Viking HF-110 engine. This engine needs a 3/8” ID fuel inlet line from the tank and a ¼” return line back to the top outboard corner of the wing tank. The UL Power engine recommends a ½” ID inlet line and a 3/8” ID return line. For both engines, it is very important to…


Added by Larry Zepp on July 11, 2012 at 8:53pm — 8 Comments

Aluminum Knife Plans in PDF format



Several people have requested these plans in PDF format instead of MS Word. The PDF file is attached.


Best Regards,  Larry Zepp  CH 650B builder, Fort Wayne, IN

Added by Larry Zepp on June 18, 2012 at 10:56am — 4 Comments

Reducing Pivot Point Friction in your Aircraft


By Larry Zepp, Zodiac 650B Builder, Fort Wayne, IN


Reducing friction and wear between aluminum and steel at the pivot points in your aircraft is a good goal. Usually, space is a problem – how do you add a bearing or bushing without changing the aircraft design?


A combination of space age technologies has offered an elegant…


Added by Larry Zepp on June 12, 2012 at 8:40pm — 2 Comments

Aluminum Knife Plans

Improved Aluminum Knife Plans


Even though the Olfa scoring knife gets the job done when cutting aluminum sheet, I kept thinking there must be a much better way to cleanly cut out aluminum sheet. Knife blades are designed to cut soft and flexible materials. When we use an Olfa or utility knife blade to cut T6 tempered aluminum, the aluminum resists spreading at the cut line and requires many repeated scores. Even though the aluminum is thin, the blade must cold flow the…


Added by Larry Zepp on June 11, 2012 at 7:57pm — 3 Comments

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