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Tank Sealant

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Joined: 18 Jan 2011
Posts: 3
Location: Madison, WI

PostPosted: Wed Jun 28, 2017 3:06 am    Post subject: Tank Sealant Reply with quote

Just wanted to add that my Pulsar III with factory built wings (completed 2003) also shows a slight expansion along the full perimeter of the fuel cell (upper wing surface only) . On my plane this became evident within six months after painting and has not progressed since. No evidence of leaks. There has never been any ethanol in my tanks. Are there any series III factory built wings without this joint visible? The several I’ve seen have it. Bill
On Jun 13, 2017, at 12:26 PM, BARRY NORMAN <barrynorman(at) (barrynorman(at)> wrote:

I'm still having problems with tank seepage near the end plates where is looks like the fuel is finding it's way out through very small passageways in the fiberglass or connection points. I use PRO-SEAL FUEL TANK SEALANT on the end plates and I think that works pretty well. I believe the issue is, the epoxy used to glue the leading edge to the spars at the factory was affected by ethanol in the fuel which caused it to expand and crack all along the attachment point on the spar. You can see the malformation on the outside of the wing where it was exposed to the fuel and expanded. I believe fuel is traveling down these cracks and creating small leaks. There is a product called PR-1005-L BUNA-N-SLOSH COATING sold by aircraft spruce that I'm thinking about using to coat the cracks in the epoxy at the attachment points. Has anyone used this sealer and have information on it's effectiveness? I believe the structural attachment of the leading edge to the spar is still very sound but want to stop anymore expose to fuel if I can.

I'm also finishing up an update to the panel which includes 2 GRT Horizon HX displays and a new Stratus Mode S transponder that will make the plane ADS-B compliant. Hope to have it all ready to go by reunion time.

Barry Norman

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