Section 4, Fuel System, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

03262010 Initial Creation 3/26/2010
09162011 Update 9/16/2011
10032011 Update 10/03/2011
01062012 Edited Edited and Corrected figure numbers 1/06/2012
10012012 Update Change to new 24 gallon fuel tank 10/1/2012
11272012 Update 11/27/2012

Page 1 of 8
 Section 4, Fuel System, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary to assemble the fuel tank and related fittings for installation in the SeaRey SLSA aircraft.

2.0 Applicable Documents

None

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Marker, Felt Tip
 Ruler
 9/16” Wrench
 Screwdriver, Phillips Head
 Vise

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Protective gloves
 Paper Towels
 Permatex® Aviation Form-A-Gasket® No. 3
 Permatex 1B Sealant

3.3 Procedure

Page 2 of 8
 Section 4, Fuel System, SeaRey, LSA

Fuel Pickup Fuel Sensor

Finger Strainer

Fuel Return
3/8” Hose Barb Accepts
1/4”x1/4”
Barb

Tank Vent

¼” Sump Drain
Fuel Tank

Fuel Fill

Figure 1. Fuel Tank

Parts
Installing the Fuel Supply and Return Barb in Fuel Tank

1.1 Coat the (Fuel Pickup) Finger Strainer, Std (#2810-020) threads with Permatex No. 3 Sealant (#3230-097) and thread into the fuel tank
(Part # 2810-029) ¼” FPT fitting at the bottom front of tank above the sump drain barb and tighten.
1.2 Coat the (Fuel Pickup) Hose Barb, 3/8” x ¼” (3/8” Hose Barb x ¼” Male Pipe) threads with Permatex No. 3 Sealant (#3230-097) and thread
into the Finger Strainer, Std (#2810-020) and tighten.
1.3 Coat the (Fuel Return Barb) Hose Barb, ¼” x ¼” (1/4” Hose Barb x ¼” Male Pipe)(Part # 7310-006) threads with Permatex No. 3 Sealant
(#3230-097) and thread into the fuel tank (Part # 2810-029) at the top forward pilot side wall.

Page 3 of 8
 Section 4, Fuel System, SeaRey, LSA

Fuel Gauge Sender (#2810-008)

Supplied Parts

Mounting
Float Arm
Screws

Gasket Rheostat

Support Arm

10-3/8”

8-15/16”

Figure 2. Support Arm Prep

2.1 Remove Rheostat housing from support arm by removing the two sheet metal screws on the side.
2.2 Mark the Support Arm 10-3/8” below the mounting flange with a felt tip marker.
2.3 Cut the Support Arm across the 10-3/8” mark.
2.4 Make a small mark on the Support Arm 8-15/16” below the mounting flange.

Page 4 of 8
 Section 4, Fuel System, SeaRey, LSA

3/4” Mark

Figure 3. Float Arm Prep

3.1 Mark and cut the float arm 10-1/2” from the bend in the float arm that supports the float. Debur / smooth the cut area.

Bend 90
degree at mark

Figure 4. Bending the Float Arm

4.1 Using a vice, bend the float arm 90 degrees at a distance of 3/4” from the previously made cut. Note: The bend should be in the same plane as the
float and in the direction pointing away from the float.

Page 5 of 8
 Section 4, Fuel System, SeaRey, LSA

90 degree
bend into hole Plastic clip

Figure 5. Attaching Float Arm to Rheostat

Note: In the following step, be careful not to damage the rheostat housing!
5.1 Insert the 3/4” bend in the float arm into the plastic wiper bracket hole. Snap the float arm firmly into place being careful not to damage the
rheostat housing.

6.1 Place the cork gasket over the support arm and next to the flange for later use.
6.2 Reinstall the rheostat housing to the support arm, positioning it so that the tab for the lead
terminal wire is pointed toward the mounting flange; and the center of the wiper bracket
hole is directly abeam of the 8-15/16” mark made previously above.
Cork Gasket

Note: In the following step, make sure the electric mounting tab is firmly
seated!
6.3 Connect the lead terminal to the rheostat assembly by pushing the connector firmly onto its Lead Terminal
tab.

Wiper Bracket
hole over 8-15/16”
mark

Figure 6. Assembling the Fuel Sensor

Page 6 of 8
 Section 4, Fuel System, SeaRey, LSA

Figure 7. Mounting the Fuel Sender to the Fuel Tank

7.1 Carefully place the Fuel Gauge Sender (#2810-008) into the tank by feeding the sensor, float first, into the tank mounting hole.
7.2 Orient the float inside the tank so it is aiming toward the center of the tank at an angle and aligning the special screw hole configuration of the
Sensor mount plate and the fuel tank threaded inserts.
7.3 Place a small bead of Permatex 1 Sealant (3230-099) on both sides of the cork gasket.
7.4 Align the sensor mounting flange screw hole pattern with the cork gasket and the fuel tank mounting holes.

Page 7 of 8
 Section 4, Fuel System, SeaRey, LSA

Fuel Gauge Sender

Fuel Gauge Sender

Fuel Tank

Figure 8. Completed Fuel Tank

Parts

8.1 Using five #10-32 x 1/2” Machine Screws (Supplied with the Sensor), mount the Fuel Gauge Sender (#2810-008) flange to the fuel tank installing
the screws into the threaded inserts in the tank.

Page 8 of 8