sonex aircraft LLC
511 Aviation Road |
Oshkosh, WI 54902 |
Tel. (920)-231-8297 |
Fax. (920)-426-8333 |
www.sonexaircraft.com
Installing the Oops Fittings
(Rev A 05/03/2013, 2 Pages)
The Oops Fitting is a replacement / repair for fuel tank fittings which have been broken lose in the tank. They are available in two sizes so any fitting in the tank can be replaced:
1/8 NPT - Part Number SNX-G01-20
3/8 NPT - Part Number SNX-G01-30
2.Use a step drill to drill the damaged fitting from the tank. If drilling the large 3/8 NPT fitting do not drill larger than 7/8" with the step drill. If drilling a 1/8 NPT fitting do not drill deeper than the 9/16" step of the drill. Some of the damaged fitting will still remain in the tank after this step is complete.
Oops Fitting Components
Internal Fitting
and O-Ring
Wrench Flat
Nut and External O-Ring
Recommended Tools and Materials
Review these instructions to determine specifically what additional parts you may need to complete your particular installation:
qX-Acto and/or utility knife
qStep Drill, Approximately 1/8" to 7/8"
qAdjustable wrench (2)
qFlexible wire (safety wire, electrical wire, etc.)
q9/16" Dia. drill bit for installing a 1/8 NPT fitting
q1" Dia. drill bit for installing the 3/8 NPT fitting
q3/4" diameter washer
Removing the Existing Fitting
1. Purge all fuel and fumes from the fuel tank.
Explosive Vapor!
Avoid serious injury or death. Remove all fuel and explosive vapor from the fuel tank before
DANGER performing this repair.
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A step drill (left) is used to remove most of the existing fitting
(right). Do not drill deeper than indicated in step 2 or the hole may be too large for the Oops fitting and a new fuel tank will be required.
3.Remove the remainder of the damaged fitting with a standard twist drill. Use a 9/16" diameter drill bit to remove the remainder of a 1/8" NPT fitting. Use a 1" diameter drill bit to remove the remainder of a 3/8" NPT fitting.
4.Use a sharp knife, fine file, and sandpaper as needed to smooth the area around the entrance and exit of the hole so the o-rings of the Oops fitting have a smooth surface to seal against.
Important: If replacing the 3/8 NPT fitting, remove the large ridge inside the tank where the old fitting was. The smoother and flatter this area is the better the seal will be between the Oops fitting and the tank.
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