Service difficulty report · Fuel Tank · Diamon DA42NG

Difficulty date
August 11, 2025
Submitted
August 28, 2025
Operation
General aviation
Aircraft
N793ER
Make and model
Diamon DA42NG
Aircraft serial
42N484
Aircraft time
976 hours
Engine
Austro E4
Propeller
Mtprop MTV6R
Part
Fuel Tank
Part number
D4D28172100
Condition
Cracked
Location
Zone 500
Part time
976 hours
Stage of operation
IN
How discovered
V
Nature of condition
K
Precautionary procedure
K

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

DURING ACFT ANNUAL INSPECTION, WINGS ARE REMOVED AS PART OF 1000 HR ITEMS CHECK. WING FUEL TANKS ARE REMOVED FOR INSPECTION AS PART OF 1000 HR CHECK. EACH WING HAS (3) FUEL TANKS INLINE CONNECTED BY HOSE SECTIONS, FOUND MULTIPLE INBD TANKS LEAKING SMALL AMOUNTS OF FUEL. FUEL TANKS CONSTRUCTED USING MULTIPLE SPOT WELDS ABOUT 3/8 INCH DIAMETER, TANKS EXPERIENCE SMALL CRACKS AT SPOT WELDS & SLOWLY LEAK FUEL OVER TIME. EXPERIENCED MULTIPLE CRACKED TANKS ON MULTIPLE ACFT. OUR COUNTERPART UNIVERSITY IN DAYTONA BEACH FLORIDA HAS ALSO EXPERIENCED 8 CRACKED FUEL TANKS & (1) WITH ONLY 200 HOURS ON TANKS SINCE NEW. REPLACEMENT FUEL TANK SUPPLIES HAVE BECOME AN ISSUE & NO SHOPS WANT TO ATTEMPT REPAIRS ON CURRENT DESIGN.

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