Two Ways To Make A
Refueling Station

Warning: The Challenger BTT web site, any of its committee members or private party, Larry Davis, does not endorse or encourage anyone to build either refueling station! Gasoline is very flammable and a spark may cause a fire and/or injury! Depending on fuel storage location, may be prohibited by property owner or local law ordinance.

Refueling Station #1
By: Art Freeman

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Why spend the money for this elaborate of a refueling station for your plane?

Well, it's a bit pricey, but if you are sporting "wing tanks" where you need to get up on a step ladder to refill your fuel tanks, I doubt you would like it very much having to lift and try pouring fuel from a 5 gallon can into the tanks. Also, I have never seen a 5 gallon fuel can "NOT LEAK" from around the fuel spout. Don't know about you, but I sure would not like having gas running down my wings and onto the Lexan windows.

Additionally, if you have the cash for this type of setup, you would be far better off using this "CLEAN" way of refueling then trying to use those leaky 5 gallon cans to refuel your bird, even for the standard 10 gallon, in fuselage fuel tank.

When refueling my Challenger II, I can pump 20 gallons faster then I can pump gas at a gas station into my car. This is a really good and clean outfit for refueling your plane.


    12v Fuel Pump and Fuel Meter to deliver your fuel as high as seven (7) feet above fuel pump.
    20 Gallon Neoprene Fuel Barrel, bought empty from a "car wash" and completely washed out.
    Dolly, can be bought at most any retail outlet.
    12v Jump Start Battery Pack. Be sure to get a good one.
    3 ea. Alligator Battery Clamps to connect the pump cable to the jump start battery pack and to plane ground.
    1 ea. Tie Down to secure the 20 gallon barrel to the dolly.

Fill-Rite 1202 PUMP
12 Volt DC Fuel Pump 13 GPM

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  1. Thermally protected, UL/cUL listed, explosion-proof, 1/4 HP motor
  2. 2" NPT, no tank adapter needed
  3. 3/4" x 10' hose, manual nozzle and 15' power cable
  4. 1" polymer adjustable suction pipe
  5. Positive displacement, rotary vane configuration
  6. Ball bearing construction, no lubrication required
  7. 30 minute duty cycle
  8. Pump may be padlocked

Fill-Rite 807C Flow Meter
Fill-rite Meters Provide Precision And Durability In A Cost-effective Design. The Series 800c Meters Exclusive Unicast Component Mounting Configuration Assures Consistency, Particularly In Gravity Flow Applications. Fill-Rite's line of mechanical meters are designed to meet the stringent demands of customers who need to monitor fuel usage accurately and dependably. Rugged construction, easy to read numbers, and the flexibility of horizontal or vertical positioning are just three features of these superior meters. Plus, all can be field calibrated for the utmost accuracy, regardless of the fluid.
  1. 5 to 20 GPM
  2. Accurate to + 1%
  3. Totalizer to 99,999.9
  4. Registers to 99.9-gallons
  5. 20 GPM 3/4" or 1" ports
  6. Large easy to read numbers
  7. Quick reset knob
  8. Flexible flow ports can be positioned vertically or horizontally
  9. UL/CSA listed options
  10. Gallon or liter reading 3/4" or 1" ports
  11. Strainer for gravity-flow applications traps tank contaminants
  12. Teflon or nickel coatings increase selection of compatible fluids
  13. Designed for metering diesel fuel, gasoline, kerosene, mineral spirits, stoddard solvent and heptane
  14. NOT suitable for use with WATER)
  15. BSP threads

For best pricing on the John Ellsworth Company fuel pumps and meters, look at their eBay site store. Pricing will be higher at the John Ellsworth Company catalog sales and internet site.

Prices as of 12/2005
    $198.50 - 12v Fuel Pump
    $119.00 - Fuel Meter
    $50.00 - Aprox. Shipping on Pump & Meter
    $10.00 - 20 Gallon Neoprene Fuel Barrel
    $65.00 - Dolly
    $55.00 - 12v Jump Start Battery Pack
    $6.00 - 3 ea. Alligator Battery Clamps
    $5.00 - 1 ea. Tie Down
    $508.50 - TOTAL

Refueling Station #2
By: Larry Davis

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After breaking my back bending under the wing of my Challenger to refuel, I built a re-fueling station. I used to dread coming back to the airport and having to pour gas for 20-30 minutes after each long flight.

I bought a hand truck/dolly at "Big Lots", an auto electric fuel pump, fuel filter, and put it all together. I used a battery charger, I already had, to power the fuel pump. The red hose end came from an old fuel pump I had.

The electric fuel pump was the expensive item ($90.00) as I wanted one that would really pump fuel. This one is rated at 10psi and 72gph. It fills up the tank in a hurry!

I put an 18" piece of 1/4" copper tubing on the end of the input hose so the hose will pick-up fuel all the way to the bottom of a fuel can. Made the hose long enough to reach into a can sitting on the dolly. That way, I can use the can on the cart or just stick the copper tube in a can that's sitting on the floor. The coffee can is to store the ends of the hoses so fuel doesn't drip on the floor. I switch full cans for empty ones, on the cart. That way, there is no poring of fuel in the hangar. I used a battery charger instead of a battery as I wanted NO sparks when connecting and disconnecting. After the filler hose nozzle is in the airplane fuel tank and the pick-up tube is in the tank with fuel, I plug in the battery charger away from the cart. No sparks!

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$120.00 For this system.