> What was your total fuel capacity > when finished (header plus wing tanks)?
I realize you didn't ask me this question, but as a general rule, but if you have about a half inch of foam all the way around, each inch of stub wing will yield slightly less than half a gallon, so if you have two tanks, and they are 20" long each, you'll end up with about 19 gallons of capacity. But keep in mind that you're supposed to install the filler so that 5-10 percent of the tank can't be filled, to provide expansion space so when the fuel gets warm it won't run out on the tarmac. So that means you'll have maybe 17 to 18 gallons if your tanks are 20" long. There's a drawing near the top of http://home.hiwaay.net/~langford/misc.html that shows the outline and how this is calculated. There's also a bunch of excruciating detail on building composite wing tanks, including the filler that Brian mentioned, at http://home.hiwaay.net/~langford/swings.html . Whatever you do, keep in mind that there's no such thing as "excess epoxy" when it comes to finishing the inside of the tanks. Running wire, and doing little stuff here and there that will hopefully someday yield a flying aircraft... Mark Langford, Huntsville, AL N56ML "at" hiwaay.net see KR2S project at http://home.hiwaay.net/~langford