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NEWKIT – FFC Installation Accessory Kit
Available now on the Airparts.aero Marketplace.
The NEWKIT is a comprehensive installation and auxiliary hardware package designed to facilitate the professional mounting and integration of FFC (Flexible Fuel Cell) systems and associated fluid-transfer components. In the aerospace sector, particularly within general aviation and rotorcraft, Flexible Fuel Cells are essential for maximizing fuel volume within irregularly shaped wing or fuselage cavities. The NEWKIT provides the specialized seals, fasteners, and installation tools required to ensure a "drop-in" fit while maintaining the absolute leak-proof integrity of the aircraft's fuel system.
Unlike generic hardware kits, the NEWKIT is tailored for the unique chemical and mechanical requirements of nitrile and urethane-based fuel bladders. It includes the critical interfacial gaskets and anti-chafe barriers necessary to prevent the bladder from coming into direct contact with the airframe’s metallic structure—a common cause of premature cell failure. For the A&P mechanic, the NEWKIT eliminates the logistical burden of sourcing individual part numbers for fuel-drain valves, vent fittings, and access-plate seals during a cell replacement or fuel system overhaul.
Key Features
Fuel-Resistant Gasket Set: Includes high-compression gaskets (typically Nitrile or Fluorosilicone) that are chemically inert when exposed to Avgas, Jet A/A-1, and biocidal fuel additives.
Corrosion-Inhibiting Fasteners: Features cadmium-plated or stainless steel screws and nut-plates designed for high-vibration environments, ensuring the fuel cell access plates remain secure.
Anti-Chafe Protection: Provides specialized tapes or barrier strips that line the fuel tank cavity, protecting the flexible bladder from sharp edges and rivets.
Drain & Vent Valve Hardware: Includes all necessary O-rings and crush washers for the re-installation of "Quick Drain" valves and vent line fittings.
Lubricant & Sealant Packets: Contains aerospace-grade O-ring lubricants (such as Parker Super O-Lube) and fuel-system thread sealants to ensure a leak-free assembly on the first attempt.
Technical Specifications
Part Number: NEWKIT
Application: Flexible Fuel Cell (FFC) Installation / Maintenance
Material Class: Fuel-Grade Elastomers and Aerospace-Spec Hardware
Chemical Resistance: Fully compatible with MIL-DTL-5624 (Jet Fuel) and ASTM D910 (Avgas)
Temperature Rating: -65°F to +180°F (-54°C to +82°C)
Governing Specifications: TSO-C80 (Flexible Fuel and Oil Cell Material)
Certification: FAA-PMA / OEM Accessory Kit
Aircraft Compatibility
Cessna Single-Engine Series: 180, 182, 185, 206, and 210 (Wing Cell models).
Beechcraft Bonanza & Baron: 33, 35, 36, 55, and 58 series fuel systems.
Piper PA-23 Apache/Aztec: Wing tank and auxiliary tank installations.
Rotorcraft: Various light helicopters utilizing flexible crashworthy fuel systems.
Note: The NEWKIT is frequently used as a companion kit to Aero-Tech, Eagle Fuel Cells, or Amfuel bladder replacements. Always cross-reference your specific cell part number with the kit contents.
Applications
Fuel Bladder Replacement: Providing all the "soft goods" and small hardware for a new cell installation.
Annual Inspections: Resealing fuel access panels and replacing aged gaskets to prevent weeping leaks.
Fuel Leak Troubleshooting: Used to overhaul the "Bolt-In" flange areas where leaks commonly occur at the wing/cell interface.
Why Choose the NEWKIT?
Fuel system maintenance is a high-stakes task where a single missing O-ring or a re-used gasket can lead to an "AOG" (Aircraft On Ground) situation due to fuel seepage. Choosing the NEWKIT ensures that the Material Compatibility and Physical Dimensions of every seal are specifically matched to FFC standards. Reusing old gaskets or using "hardware-store" rubber in a fuel system can lead to swelling, delamination, and eventual fuel contamination. The NEWKIT provides the quality-controlled components required to maintain the safety margins of your aircraft’s fuel system and ensures compliance with the manufacturer’s installation manual.
The NEWKIT utilizes the engineering principle of Compression-Seal Integrity. In a flexible fuel system, the "seal" is achieved by sandwiching the bladder flange between an internal and external metallic ring. The gaskets provided in the NEWKIT are designed with a specific Durometer (Hardness) that allows them to "flow" into the microscopic surface imperfections of the airframe, creating a Hermetic Barrier.
Tech Tip: When installing the gaskets included in the NEWKIT, always follow the "Star Pattern" torquing sequence for the access plate bolts. This ensures even pressure distribution across the gasket surface, preventing the "pinching" or "waviness" that often results in slow fuel weeps.
Note: The NEWKIT is a maintenance support package. Fuel cell installation is a complex procedure that often requires specialized "fishing" tools to align the cell within the wing. Always ensure the tank cavity is vacuumed clean and free of all debris before cell insertion. Installation must be performed by a certified A&P mechanic in accordance with the Aircraft Maintenance Manual (AMM) and the fuel cell manufacturer’s instructions.
