Fuel leak???

If you had plugged return lines, I would expect the fuselage tank to be overflowing all the time, not periodically.
Since the splash only occurs during rough handling, it implies it is a splash issue. Aged unsealing cap gaskets are a common issue, that would be the first thing I would check.

Hi,

My name is Jack Liguori.

And I recently, June 22nd, 2015, purchased an Alon A2 Aircoupe, #A29, N6353V..

Almost immediately I began to detect a very strong gasoline order in the cockpit.

At first I thought that either the bottom of the fuselage tank or the line coming out of the bottom of it might be leaking because I could sometimes see a little gas residue in that area.

But, after wiping that entire area down until it was absolutely dry I detected no more fuel residue after letting it set for a few days.

But then after a slightly hard landing I again smelled gas and saw a little gas on the bottom side of the tank.

After several contorted excursions under the instrument panel I managed to reach up over the sides of the tank and discovered that there was some gasoline 'wetness' on the top of the tank. It looked like it was running down the side of the tank and migrating to the bottom of the tank around the gas line fitting.

I wiped it all down again and for a day or so there was no more wetness while the aircraft was stationary and not flown ... or after a couple of short flights.

But, then after about a 45 minute flight I was suddenly surprised by gasoline spaying onto the windshield in flight, at about 100 miles per hour at about 4,000'.

Luckily that spraying only lasted about 20 or 30 seconds and then stopped. But, it sure got my attention ... and scared the manure out of me.

I landed ASAP, and after landing I took a good look at the gasket under the float cap. It was made of a cork like material and appeared to in OK condition.

But, I had a spare solid cap (with no float) which had a rubber gasket that looked a tiny bit thicker. So I put the rubber gasket on the float cap.

That was several days ago I have not had a chance to fly the plane again yet.

I was wondering if you have ever experienced, or heard about this kind of thing.

I understand that there are some lines leading from that fuselage tank back to the wing tanks ... and I was wondering if they might be plugged causing the tank to over fill from the engine driven pump.

Or if it was simply a case of the float cap gasket leaking ... or perhaps not entirely tight, although I thought I had tightened it properly before the flight when it sprayed???

There is an A&E at the FBO where I hangar it at ELZ in Wellsville, NY ... but, he doesn't have any experience with Aircoupes ... or Ercoupes ... so I need to reach out to some experience old hands for some help and advice.

Ergo ... anything you can offer will be greatly appreciated.

ASAP ... because I do not much relish test flying it with the possibility of another potential shower of gas on the windshield:(

Jack
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