OK, a good friend of mine (Jim Davis) has a Cherokee 235, with the original 
polyester tanks.  He had an autogas STC, and unfortunately put in autogas that 
had alcohol.  It dissolved the material in the tanks.  No Polyester is not 
something anyone should put in an aircraft if there is any chance of contact 
with alcohol, whether intentionally or by mistake, as my friend did. While 
epoxy is about twice the cost of polyester, anyone who did not use the best and 
safest material for their fuel tanks is using a false economic argument.  From 
my 38 +years experience with aircraft, it is just not worth it to go cheap.  

Bill Zorc
Vero Beach,FL 
RV-8 N2046F
KR-2 N7040E
A&P/ATP/CFII & former Piper employee



In a message dated 10/02/09 17:43:13 Eastern Daylight Time, 
jscott.pi...@juno.com writes:

On Fri, 2 Oct 2009 17:46:07 +1000 "Phillip Matheson" 
<phillipmathe...@bigpond.com> writes: 
> Fred, 
> 
> Polyester should work just fine.  That's what Piper used to build 
> the tip 
> tanks on the Cherokee 235 and Cherokee 6.  Polyester has it's 
> difficulties 
> in certain applications, but it works quite well for a fuel tank. 
> 
> ------------------------------------------------------ 
> 
> DO NOT USE Polyester!!!!!!!!!!!!!!!!!!!!!Do you REALLY want to take the 

> chance????? 
> 
> DO a test yourself and let us know your results!!!!!!!!! 
> put some polyester in some avgas and ULP. 
> 
> I would only USE Vinyl Ester. ( not Epoxy)  unless the manufacture says 
it's 
> OK. not someone else. 
> 
> Too many people have had problems with epoxy, I have seen what 
> leaking tanks 
> on a Lancair does.. NOT good. 
> 
> 
> Phil Matheson 

----------------------- 

Wow!  That's a lot of exclaimation points and question marks.  The 
question posed seemed to be simple enough.   
"Can anyone tell me if Polyester will work on a fuel tank application? " 
I'll stand by my answer.  Yes it will, and there are tens of thousands of 
Cherokees flying around with Polyester tip tanks as flying proof.  Many 
have been in service since long before Ken and Stu dreamed up the KR 
aircraft.  Apparently some of you have testing data that you should share 
with Piper and the FAA that demonstrates otherwise?   

Later, a second question was posed about the tolerance of Polyester tanks 
to Alcohol fuels.  My answer was that I don't know.  Piper didn't test 
alcohol in their tanks as Alcohol contaminated fuels are not recommended 
(or allowed) by either Piper or the FAA.  Consequently, I have no 
knowledge of specific long term testing data.  I've only heard third and 
fourth hand anecdotal information on the internet, which I don't consider 
to be particularly reliable data. 

Would I really want to take the same chances with my tanks as a Piper 
Cherokee?  Simple answer.  "Yes."  However, I would not use alcohol 
contaminated fuels in my aircraft, whether the tanks were up to it or 
not.   

The original post didn't ask for a recommendation, which is why I didn't 
make one. 

Jeff Scott 
Los Alamos, NM 
N1213W 
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