Just purchased a used O-200. Having it inspected and fixed up by mechanic, but in the meantime working on my wing kit. How did some of you plumb the fuel in your wings? How did you seal up the return outlet? Did you seal up the vent and go with vented caps? Any help is always appreciated!

Views: 176

Reply to This

Replies to This Discussion

Kind of depends what you have in mind for a fuel system.  I plan on a header tank so I ran 1/2" solid aluminum lines to the trailing edge, as the header tank will have two vents going back to the wings.  Essentially copied the injected rotax fuel system that the Skytek guys in Canada came up with as it seems well thought out and fool proof to me...no need for a return line of course.  Some details on the following two links:



I did change the venting system for the fuel tanks.  Details:


Eliminated the stock venting system, details here:


Thanks Don! How big of a header tank are you using? Where did you end up placing it? Where did you buy it, or did you manufacture it yourself?

Nat, haven't got that far.  I will likely have a tank fabricated, probably 2 gallons or so...

If you don't mind me asking...what did you pay for your O-200 core and where from?


Bryan, I know you're asking Nathaniel, and he may answer, but just for add'l information, I bought my O-200 core from eBay, seller was BAS out of Boulder CO.  I intended to rebuild myself from day one. This one had ALL accessories and full logs. Was a prop strike; but everything checked out by Aircraft Specialties in Tulsa. Logs showed that the carb was rebuilt less than a year before I purchased it, as well as one of the mags.  I paid $4376, but that included truck freight from CO to DFW. VERY well packed on an old truck tire on a pallet and wrapped with about a roll's worth of the stretchy pallet wrap film.  I estimate when I'm all done with 4 new Millenium cyls I'll have about 13-14k in it.

I paid $4,500 from barnstormers. Came with all accessories. Original generator and starter. New mags. New spark plugs. All logs. Waiting to disassemble and inspect to see what upgrades I will do. Thinking of getting higher compression pistons. Will definitely get an alternator and a new light weight starter.


New from Zenith:

Zenith Planes For Sale 

Classified listing for buying or selling your Zenith building or flying related stuff...

Custom Instrument Panels
for your Zenith

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, power distribution panel, Approach Fast Stack harnesses, Dynon and Garmin avionics, and more.

Custom Upholstery Kits for your Zenith Aircraft:

Zenith Vinyl Upholstery Kits

Zenith Apparel from EAA:

Zenair Floats

Flying On Your Own Wings:
A Complete Guide to Understanding Light Airplane Design, by Chris Heintz

Builder & Pilot Supplies:

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

Aircraft Insurance:


West Coast USA:

Pro Builder Assistance:


Transition training:

Golden Eagle Aviation

Pianosa Flying Farm

Aircraft Spruce & Specialty for all your building and pilot supplies!

© 2020   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service