Today was one of those days where I should have just stayed in bed.

Today I reinstalled the front portions of the engine baffles, which I had removed so I could modify the cylinder wrap-around parts. I also took the opportunity to enlarge the hole where the prop oil line comes through the right front baffle. The original hole I made wasn't big enough, as I hadn't allowed for the retaining clamp on the end of the firesleeve.

After reinstalling the baffle, I decided to install that oil line, now that it would fit through the hole in the baffle. I quickly discovered that I had a problem. There wasn't room for it to go under the cylinders, because one of the hoses for the inverted oil system was in the way. I had intended for that inverted oil system hose to have a different routing, but I hadn't allowed for the effect of the firesleeve. After installing the firesleeve, I found that the hose was now too short to use the planned routing, as the firesleeve pushed it further way from the oil sump as it came around a corner. So, I put it above the sump, below the cylinder. Now that decision had screwed up the routing for the prop oil line.

So, the inverted oil line has to go back to its originally planned routing. I could make a new, longer hose, but I would have to order more hose, and that stuff is expensive (about $60 for the hose, $30 for firesleeve and $3 for firesleeve clamps, plus taxes and shipping). Plus it is a real PITA to put the ends on the hose. Then I had a brilliant idea. I should have learned now to beware of brilliant ideas, but some folks never learn. I noted that the fitting on the bottom of the inverted oil system tank, where the problematic hose installs, was not in the centre of the tank. It was towards the aft end of the tank. I could rotate the cylindrical tank in its mount, and that would move the fitting towards the front of the aircraft. A quick check showed that this would allow the hose to go back to its originally planned routing, making room for the prop oil line. Great. I'll save a few dollars because I won't need to order $100 of hose.

But, because I planned to rotate the tank in its bracket, the angle of the fittings on the top and bottom would now be wrong. I would need to remove those fittings, and reinstall them at the new angle. Off comes the tank, put it between my knees, put a wrench on the top fitting, and twist. Nothing. Harder. Nothing. That fitting is really in tight. Grab the heat gun, to heat up the tank, which will cause it to expand a bit - that worked. Top fitting came out.

Now for the bottom fitting. Same problem. Try heat. I can't keep the tank from turning between my knees. So, I grab another wrench and put it on the fitting on the side of the tank, so I can keep the tank from turning. These are long wrenches, so I have lots of leverage. Leverage is good. Finally I get the bottom fitting out, and I am happy.

Then I look at the tank. I put so much force on the side fitting, to keep the tank from turning, that the weld is cracked, and the tank is bent. Arrgh. Tim the Tool Man strikes again.

Here you see the deformation around the fitting in the side of the tank.

The fitting at the top of the picture was originally coming straight out of the tank, with a line through the fitting going straight through the centre of the tank. Now you can see how the fitting is canted off to the right, due to the deformed tank.

Off to the Aircraft Spruce web site to price out a new inverted oil tank - $384.95!! Ouch. All so I could save less than $100 of hose. Arrgh. Maybe I could get the tank straightened out and re-welded. The powder coating would have to be ground off, which risks thinning out the aluminum. It would look like crud afterward. And, if this tank fails I'll lose a whole bunch of oil, which could lead to engine failure or a fire. It isn't worth risking a $100,000 aircraft, and our lives to try to salvage a $400 tank.

I sent an e-mail to Raven Aircraft, to ask them if their inverted oil tank is compatible with the Christen system, and to get a price. The Raven system is reputed to work just as well as the Christen system, and it is apparently quite a bit cheaper. Plus they have an optional smaller diameter tank that may help my space issues.

Needless to say, I didn't get any more work done today after the tank tragedy. I'm drinking a beer right now, and I think I'll drink several more.