09/30/2026
Last week, the Michigan Flight Museum called us with a rush job on the fuel tank for their Douglas C-47 Skytrain.
Manufactured in 1944, this main fuel tank had developed a major leak and was leaving puddles all over the hangar. We were excited to help, and had the tank repaired and returned in less than 24 hours!
Keep reading if you’re interested in how we approached this repair:
- First, we thoroughly flushed the tank with water to remove any remaining fuel and contaminants.
- Next, we performed a dye penetrant test to identify and confirm the ends of the crack.
- We prepared the crack for welding by drilling a hole at each end. This helps prevent the crack from continuing to grow. We also ground the repair area down so the added material would not extend beyond the original tank dimensions. This is especially important because these tanks have an extremely tight fit inside the aircraft.
- The most critical step was purging the tank with argon. Removing oxygen from the tank is essential before welding. Since argon is heavier than air, we introduced it at the low side of the tank and created a vent at the high side, allowing the argon to displace the air inside the tank. We calculated the tank's internal volume at approximately 27 cubic feet, so we flowed argon at 27 cubic feet per hour for one hour to achieve our calculated purge volume.
- With the tank properly prepared, we welded the crack. The tank is constructed from 3003 aluminum, so we used 4043 aluminum filler rod for the repair.
- Finally, we tested the repair. We fabricated custom caps to seal the sending-unit port and fill port, then pressure tested the tank at 1 psi while spraying the entire tank with soapy water to check for leaks. The crack repair held with no leaks.
During testing, we did find two leaks in the sealant around the fasteners. We were able to show these to the client so they could be resealed in the hangar. We also performed a dye penetrant test on the completed repair.
It’s not every day we get to work on a piece of aviation history!
Thanks to the Michigan Flight Museum for trusting us with this unique project. We’re always excited to take on a challenging repair and put our skills to work.