• If your ship is a Rotorway 162F the fuel tank outlet fittings need to be modified if they have not already been.
• I noticed this problem while I was providing flight instruction in a Rotorway 162F with Jim Terpstra. We had just refueled between flight training sessions and were flying at altitude when I thought I smelled fuel. I queried my student and he also smelled the distinctive odor of gasoline when all at once the odor intensity became unbearable. I announced "I've got it" and initiated an emergency descent and set down. Upon landing we immediately shut off all electrical components and rapidly departed the helicopter. It was then that we noticed that fuel was pouring from the underside of the body tub. It was a miracle that the fuel did not ignite and consume us and the helicopter as it poured over the hot engine and exhaust.
• Upon examination we immediately noticed that the fuel tank outlet fitting had fallen out from the bottom of one fuel tank allowing all of the fuel in both tanks (both tanks outlet lines are connected) to spray all over the engine compartment. Since I discovered this inherent design problem with this fitting installation and published the incident and the fix, I have been contacted by several individuals who found that the fuel fitting pulled out of their own fuel tanks with no more than a gentle tug or had started leaking on their own.

Here is an email that I recently received:

Orv,

Just want to drop a note to thank you for all the safety tips and fixes you have shared. From the wiring, to the extended gear, to the fuel tank mods, I have incorporated them in my machine. Without a doubt, you saved me from certain disaster on the fuel tank outlet modification. I bought my 162f with 82 hours on it. When I saw your posting I checked my fuel outlets. When I put a wrench on the right side outlet, the fitting literally fell out of the tank. Luckily, the tank only had a gallon or so but it was all over the shop floor. I still shudder when I think I almost flew the ship home 60 miles. I am convinced there is no way an owner can properly inspect the outlet on an every-flight basis which the stock configuration requires. Waiting to see seepage near a hot engine and muffler and over the battery may end up being a bit too late. It was an easy fix and great piece of mind. I have attached a picture of my son and I in the helicopter that shows the extended gear. Thanks for all your service.

Regards,

Todd Mason

To install Orv's fuel tank outlet fitting mod, you will first need to drain all of the fuel out of your fuel tanks in a well ventilated area away from any flame, gas vapors hug the ground so be careful. You do this by removing enough screws on the side of the tub to allow the rear side of the tub to be pulled away from the fuel tank to allow you to get your wrenches on the fuel tank fitting and nut.\

Disconnect the fuel line from the fuel tank fitting. Remove the fittng nut and washer. Pull the fuel tank outlet fitting out of the bottom of the fuel tank. Inspect the rubber grommet to insure that it is in good condition. If not order a new set from the factory.

Once you have the fitting removed, drill a 3/16" (or close to that) hole in the top of the fitting as seen in the photo below.

For complete installation instructions go to Orv's web site at: (Click the Link): http://www.flywithorv.com

VP, LLC makes these fuel tank fitting retaining washers and provides them to anyone who would like them.