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DJI Agras T100 OEM Mist Spray Boom Housing Kit

DJI Agras T100 OEM Mist Spray Boom Housing Kit

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DJI Agras T100 OEM Mist Spray Boom Housing Kit — OEM spray bar assembly kit, atomized mist delivery housing system, and agricultural drone spray distribution component.

🇺🇸 U.S.A. FIRST

Ares Acres LLC is a U.S.-based authorized DJI Agras reseller supporting American agricultural drone operators with genuine DJI Agras OEM replacement parts, accessories, and field-ready inventory.

FREE & FAST Shipping is included for all U.S. customers.

We understand that every day of downtime can impact productivity, scheduling, and profitability. That's why we focus on providing fast fulfillment, responsive customer support, and reliable access to the parts operators need most.

Spray geometry is the whole application. The boom housing is what holds that geometry — and when it cracks or warps, the aircraft still flies the line, still reports normal, and still lays down a pattern that is quietly wrong. That is the expensive kind of failure, because you pay for it in the crop instead of on the invoice. American operators fix boom structure before a treatment window, not during one.

We use specialized technicians to verify and dispatch the Mist Spray Boom Housing Kit ordered.

Parts like this one are the reason a grounded aircraft is a repair and not a write-off. A single component held in U.S. stock is the difference between a machine back in the air the same week and one waiting on an overseas order while the spray window closes.

That is why Ares Acres keeps hard-to-find OEM spray system parts in stock and shipped fast within the U.S.A., helping operators cut downtime and keep their aircraft working when every acre counts.

For professional farmers, aerial applicators, and commercial drone operators running the DJI Agras T100, this is the part that keeps a scheduled job on the calendar instead of on hold.


✅ Compatibility Guarantee

  • Guaranteed compatible with the DJI Agras T100
  • Same Day Shipping
  • FREE & FAST U.S. Shipping

📦 Package Includes

  • 1 × DJI Agras T100 OEM Mist Spray Boom Housing Kit
  • Integrated spray bar housing assemblies
  • OEM structural mounting components
  • Protective spray system covers
  • OEM protective packaging

🔧 Component Overview

The DJI Agras T100 OEM Mist Spray Boom Housing Kit is a precision-engineered spray distribution assembly designed to support and protect the aircraft's atomized spraying system during demanding agricultural flight operations.

Designed specifically for the DJI Agras T100 platform, this OEM housing kit forms a critical portion of the spray delivery architecture responsible for directing, protecting, and stabilizing the aircraft's mist spraying assemblies during commercial application missions.

Every acre sprayed depends on consistent droplet distribution, stable flow characteristics, and reliable spray system performance. The spray boom housing is the structural foundation that supports critical spraying components while maintaining proper positioning throughout demanding field operations.

Constructed using reinforced OEM composite materials and impact-resistant structural housings, the assembly is engineered to withstand:

  • Continuous agricultural deployment
  • Chemical exposure and fertilizer residue
  • High-vibration flight conditions
  • Repeated transportation cycles
  • Environmental debris
  • Field handling and maintenance procedures
  • Long-duration spraying operations
  • Harsh commercial agricultural environments

The spray boom housing system protects spray delivery components while helping maintain consistent application performance across row crops, specialty crops, orchards, vineyards, and broad-acre agricultural operations.

A damaged, cracked, warped, or improperly functioning spray boom assembly can negatively affect spray consistency, component alignment, operational efficiency, and overall aircraft productivity.

This is a spraying-system-critical OEM component essential for maintaining reliable DJI Agras application performance and long-term fleet readiness.

Separate a flow fault from a geometry fault before you order any part. Set the aircraft on a stand with clean water in the tank, run the spray system at working settings, and watch each outlet on its own rather than looking at the boom as a whole. What you want to see is a symmetric, evenly filled pattern of the same size and density at every position. One outlet that is weak, ragged, one-sided, or dripping is a nozzle, screen, seal, or line problem. Outlets that all look correct while the deposit on the ground is uneven is a structural problem, and that is this part.

Check position with a tape rather than only by eye. Pick a fixed reference on the airframe and measure to the same point on each outlet, then compare the reading against the mirrored position on the opposite side. You are not looking for any published dimension, only for the two sides to agree with each other. A housing that has been shoved fore or aft, pulled inboard, or rotated on its mount shows up immediately in that comparison and will not show up at all when you sight along the boom, because the shift is in a different plane.

Run the system pressurized and watch the outlets for movement. Spray lines pulse, and a housing that has cracked or lost clamp at a mounting point lets its outlet twitch or wander in time with that pulse. A sound assembly stands still. This test finds the fault that hides on the bench, because a crack that is closed and invisible with everything switched off opens under pressure and vibration, which is exactly the condition the aircraft flies in.

Read the stains on the aircraft. A nozzle that has drifted off its intended angle leaves a witness mark where it should not: a wet band on the underside of an arm, a crusted deposit on a landing leg, residue on a sensor face, or a clean stripe washed through the dust on a panel. Those marks record where the spray has actually been going for the last several tanks, and they are often the first hard evidence that a housing has moved rather than a nozzle having worn.

Learn to tell crazing from a crack. Fine, shallow surface lines spread over a broad area, with no particular direction and no relationship to a fastener, are ultraviolet and chemical crazing; they are a sign of an aged part but not by themselves a structural failure. A single line that runs out of a mounting boss, crosses a moulded radius, or travels along a load path is a crack. Put a bright light on the far side of the housing in a dark shed and look from the front; a through-crack lights up as a fine bright line and a craze pattern does not.

Wet the assembly and look for weeping at every joint. With clean water in the system and the pump running, wipe each fitting and seam dry and then watch it for a minute. A bead that reforms in the same place is a seal, a cracked fitting boss, or a housing that is no longer clamping its component square. Small leaks matter more on a spray aircraft than their size suggests, because the liquid ends up in structure, in connectors, and on parts that were never meant to be wet.

⚙️ Functional Purpose

The Mist Spray Boom Housing Kit is designed to:

  • Support spray system alignment
  • Protect critical spraying components
  • Maintain consistent spray geometry
  • Reduce vibration-related wear
  • Improve long-term spraying reliability
  • Support accurate product application
  • Protect internal spray assemblies
  • Improve operational durability

A damaged housing assembly may contribute to:

  • Inconsistent spray coverage
  • Misaligned spray components
  • Increased maintenance requirements
  • Reduced spraying efficiency
  • Premature component wear
  • Unexpected field downtime
  • Higher long-term operating costs

Flush and depressurize before anything comes apart. Run clean water through the system, relieve the pressure, and drain the boom into a container rather than onto the shop floor. Residue left in a boom is closer to concentrate than to tank mix, so wear the gloves and eye protection you would wear when loading, and keep the drained liquid for proper disposal. This step also stops the job from turning into a chemical spill the moment a fitting comes loose.

Take the fluid lines off before the structural fasteners. Working in that order means you are never holding the weight of an assembly with one hand while fighting a stiff hose with the other, which is how fittings get cross-threaded and housings get dropped. Label or photograph each line where more than one could plausibly go back in the same place, and cap or bag the open ends so grit does not find its way into the plumbing while the job is open.

Support the assembly as the last fastener comes out and never let it hang on its hoses or its wiring. A boom section swinging on a fluid line stresses the fitting boss and the barb, and it strains a harness at the exact point where you will not look for damage later. Have a second pair of hands or a support under it, and keep the aircraft itself properly supported so nothing is resting on the spray hardware while you work.

Treat every threaded plastic fitting as fragile and start all of them by hand. Cross-threading a fitting into a composite boss is the most common way this job goes wrong, and the damage is usually not obvious until the system is pressurized. Turn each fitting backwards until you feel it drop into the thread start, then run it in by hand as far as it will go before any tool touches it. Snug is the target, not tight; overtightening splits the boss and the split may not show until it is under pressure in the air.

Replace the soft parts rather than reusing them. O-rings and gaskets that have lived in chemical take a set, harden, and pick up swelling that makes them look serviceable while sealing poorly. Fit new seals where the kit or your service documentation provides them, use the lubricant the documentation specifies rather than whatever grease is on the bench, and make sure a seal is in its groove and not pinched on the face before the joint closes.

Prove the repair with water and pressure before chemical goes anywhere near it. Reconnect, refill with clean water, run the system up, and walk the whole boom looking for weeping at every joint, then check each outlet for a symmetric pattern. Take the aircraft to a low hover and look again, because vibration finds joints that a static test does not. Finally, recheck the mounting fasteners after the first flight; composite joints settle, and a fastener that was correct on the bench can be loose after a tank.

⚠️ Common Replacement Indicators

Spray boom assemblies live with vibration, chemical contact, transport stress, and demanding field conditions. Replacement may be recommended when operators observe:

  • Visible housing cracks
  • Impact damage from transport or field operations
  • Warped structural components
  • Broken mounting points
  • Excessive vibration during spraying
  • Component alignment issues
  • Chemical-related deterioration
  • Physical wear from long-term use
  • Reduced spray system stability
  • Preventative maintenance replacement

Diagnostic note: check the housing before you start adjusting nozzles. A boom that has taken a strike or warped from chemical and UV exposure changes nozzle angle and spacing without anything looking obviously broken — and no nozzle setting corrects a geometry problem. Sight down the boom against a straightedge and compare left to right; a boom that is out on one side produces a pattern that is heavy on one side, which reads on the ground as streaking rather than as a fault. Grab each housing and feel for movement at the mounting points; play there becomes crack propagation under vibration. Hairline cracks at mounting features do not stabilize — replace, do not patch.

What kills a spray boom housing:

  • Crop, ground, and obstacle strikes on the boom ends
  • Chemical residue and UV embrittling the composite over seasons
  • Continuous vibration fatiguing the mounting points
  • Transport damage from loading, stacking, and tie-down
  • Over-torquing fasteners into molded mounting features
  • Flying on after a strike with a hairline crack

Deposit on the ground that is heavy on one side of the swath and light on the other, run after run and regardless of wind direction, is a geometry symptom. Wind and ground speed problems change with conditions and with heading; a structural problem does not. If the imbalance is repeatable on a still morning and always lands on the same side of the aircraft, stop adjusting rate and look at what holds the outlets in place.

Fasteners at the boom mounts that need retightening more than once are describing a housing that has already lost the fight. Once a boss has cracked or a hole has begun to elongate, every pressure pulse and every landing works it further, and the interval between retightening jobs gets shorter each time. This is one of the few faults that gives you clear early warning, and it is very commonly treated as routine maintenance instead.

Spray that drifts or streaks worse than it used to, with nothing changed in the mix, the nozzles, or the settings, deserves a structural check. A housing that has warped in the sun or taken a knock in transport changes where droplets are released and how they interact with the rotor wash, and the result reads as poor drift control rather than as a broken part. Nothing on the controller reports it, and the operator usually blames conditions first.

Chemical residue building up in one particular place on the airframe is evidence, not just mess. Where a housing has shifted, output that used to leave cleanly now clips structure, and the aircraft slowly accumulates a crust in that spot while everywhere else stays comparatively clean. Follow the deposit back to the outlet that is making it, then check whether the outlet moved or the thing holding it did.

Any impact to the boom area calls for a proper inspection even when the assembly still functions. The spray boom sits at the widest point of the aircraft, which makes it the part that finds trailer walls, doorways, fence posts, and standing crop first. Look for cracks radiating from mounting points and on the hidden faces, check every fitting boss, and confirm each outlet still measures the same as its mirror on the far side before the aircraft goes back to work.

📐 Specifications

  • Component Type: Spray boom housing kit
  • Compatibility: DJI Agras T100
  • Application Area: Aircraft spray distribution system
  • Function: Spray assembly protection and structural support
  • Construction: Reinforced OEM high-durability composite housing
  • Installation Type: Direct-fit OEM replacement assembly

🧰 Fitment Verification Before You Order

Confirm fitment by part number before ordering. Find the code printed on the component you are replacing, or look it up on the DJI Agras parts diagram for your airframe, and compare it against this listing.

Revision suffixes are still the same part. DJI labels sometimes carry a trailing revision such as .01, .02, or .F. Those denote a production revision, not a different component. Match the base number and disregard the suffix.

Visually similar is not the same. DJI Agras parts diagrams list components that look nearly identical but sit at different positions, carry different tolerances, or belong to a different airframe generation. Ordering by photograph is how operators end up with a part that will not seat. Order by number.

Verified fitment for this listing: DJI Agras T100. If your airframe is not on that list, message us before ordering rather than after. We would rather answer a question than process a return, and so would you.

Not sure? Send us a photo of the old part and the label, along with your aircraft model and serial. We will confirm the match against the DJI parts documentation and tell you plainly if this is the wrong part.


🛠️ Installation & Handling Notes

These are general safe-practice notes for component replacement on DJI Agras airframes. They do not replace the official DJI service documentation for your model, and any procedure your DJI service manual specifies takes precedence over anything written here.

Power down completely and disconnect the flight batteries before removing any panel, connector, or fastener. Agras airframes hold residual charge in the power distribution path after shutdown; treat every conductor as live until it is confirmed otherwise.

Photograph the assembly before you disturb it. Cable routing, connector orientation, and fastener lengths on Agras airframes are not interchangeable, and the Mist Spray Boom Housing Kit is easier to fit correctly when you can see how the original sat.

Torque to DJI specification. Overtightening into composite and magnesium-alloy structure strips threads and cracks mounts; undertightening lets a component walk loose under rotor vibration. Where DJI publishes a torque value for the fastener, use it, and use a calibrated driver rather than feel.

Check the mating surfaces and seals while you are in there. A component is only as good as what it seats against. Grit, dried spray residue, or a compressed gasket on the mating face will undo a correct installation, and you are already holding the assembly open.

Test before you spray. Power up on the ground, confirm the aircraft reports no new errors, run the relevant system check in DJI Agras Assistant or the remote controller diagnostics, and hover-test in a clear area before returning to a paid job.

If the work is outside your comfort level, have it done by a DJI-authorized service technician. The part cost is small next to the airframe.


🚜 Necessary For

This component is essential inventory for:

  • Commercial DJI Agras operators
  • Agricultural drone service providers
  • Professional spraying contractors
  • Agricultural aviation businesses
  • Fleet managers operating multiple aircraft
  • High-hour spraying fleets
  • Agricultural drone maintenance facilities
  • Professional repair technicians
  • Preventative maintenance programs

While the boom is apart, inspect every soft and consumable part it carries. Check hoses for kinks, chafe where they cross a housing edge, hardening, swelling, or a section that has gone soft, and replace clamps that have lost their spring or corroded. Look at nozzle screens and any check or anti-drip valve for grit, swollen seals, or a diaphragm that is no longer sealing. These are the parts that quietly ruin a pattern after a perfect structural repair.

Look at the electrical side while you have access. Spray systems carry wiring to solenoids, atomizer motors, or sensors depending on configuration, and that wiring lives in a wet, chemical environment right at the widest part of the aircraft. Check connectors for corrosion and moisture, look for a harness that has been rubbing on a housing edge, and confirm the strain relief and clip positions are intact before everything closes up.

Check the airframe side of every mount as well as the housing itself. Look for a crushed or drawn-down boss, an elongated hole, corroded hardware, and any cracking in the structure the boom bolts to, because an impact that damaged the housing put the same load into whatever it was attached to. Fitting a new kit to a damaged mount reproduces the original fault, usually faster than the first time because the joint is already working.

This is the part that makes a repeatable application possible: outlets held where the spray plan assumes they are, droplet release into the rotor wash in the same place on every pass, a swath that matches what the flight controller thinks it is laying down, and plumbing that stays sealed at working pressure. Nothing downstream in the spray system can correct for structure that has moved, and the crop is where an unnoticed geometry error eventually shows up.

💡 Why This Part Matters

For professional operators, profitability ties directly to acres sprayed, aircraft uptime, and application consistency. The spray boom system sits at the heart of product delivery — when the housing is compromised, spray quality, maintenance load, and field productivity all move the wrong direction.

The OEM Mist Spray Boom Housing Kit helps maintain:

  • Reliable spray system performance
  • Consistent application quality
  • Protected spraying components
  • Reduced vibration-related wear
  • Improved fleet reliability
  • Long-term operational efficiency
  • Maximum spraying uptime

Without a properly functioning housing assembly, operators risk:

  • Uneven application performance
  • Increased component stress
  • Premature spray system wear
  • Unexpected field downtime
  • Higher maintenance expense
  • Lost spraying opportunities during critical treatment windows

Professional DJI Agras operators understand that protecting spray system structure is essential for maximizing uptime, maintaining application quality, and protecting revenue-generating flight operations.

After installation:

  • Assemble loose, square the boom, then torque evenly to spec
  • Check boom geometry left to right against a straightedge
  • Confirm nozzle spacing and angle match factory positions
  • Route and secure spray lines and wiring clear of pinch points
  • Run a clean-water test and verify pattern across the full boom
  • Re-check hardware after the first day back in service

Square the boom. Hold the geometry. Even the pattern. Spray it clean.

Chemical exposure sets the real service life here, and it varies enormously with what you spray. Solvent-carried formulations, emulsifiable concentrates, strong adjuvants, and high-pH tank cleaners are all harder on composites and elastomers than a simple water-based mix, and mix left standing in the boom overnight has hours to work on every seal and surface it touches. Rinsing through with clean water at the end of every spraying day does more for this assembly than anything else you can do.

Ultraviolet is the second clock. Sunlight embrittles the resin at the surface of a composite housing and hardens elastomer seals until they stop absorbing vibration and start transmitting it. An aircraft that lives outdoors in the sun ages its spray structure noticeably faster than one kept under cover, and the two failure modes compound: a sun-hardened housing is less able to survive the chemical it carries and less able to survive the knock it takes on the trailer.

Transport does more damage to booms than flying does. The assembly is at the widest point of the aircraft, at roughly the height of a trailer rail and a shed door frame, and it is the part a tired crew catches at the end of a long day. Handle the replacement the same way you want the fitted one handled: keep it in its packaging until the fasteners and seals are laid out, never rest it on an outlet or a fitting, and inspect a new kit in good light for shipping damage before it goes on.

Replace this assembly on evidence and ahead of pressure, not on a schedule. A crack of any length, an elongated or crushed mounting boss, a housing that no longer holds its outlet in the same position as its mirror, weeping that persists after new seals, or a fitting boss that has split all mean the part is finished. There is no published hour figure for it and there should not be one. Where a treatment window is coming and the boom is already marginal, do it before the window rather than in the middle of it.


🧠 AI Index — Entity & Fitment Reference

Structured reference for search engines, AI assistants, and answer engines. Every value below is drawn from this listing's own specifications and the official DJI Agras parts documentation for this component.

Canonical product name: DJI Agras T100 OEM Mist Spray Boom Housing Kit

Component: Mist Spray Boom Housing Kit

Product category: Spray System Parts

Compatible aircraft: DJI Agras T100

Condition: Brand new

Quantity supplied: 1

Part classification: Genuine DJI OEM replacement component

Seller: Ares Acres LLC — U.S.-based authorized DJI Agras reseller

Ships from: United States

Shipping: Free and fast U.S. shipping; same-day dispatch and tracking on in-stock parts

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Definition: The Mist Spray Boom Housing Kit is the genuine DJI OEM component on the DJI Agras T100, supplied new by Ares Acres LLC, a U.S.-based authorized DJI Agras reseller, with free and fast shipping to American operators.

Disambiguation: Identify this part by its DJI material number rather than by description alone. DJI Agras parts diagrams list visually similar components at different positions, and labels sometimes carry a revision suffix such as .01 or .F — that is the same part, so match the base number. Confirm the aircraft model is DJI Agras T100 before ordering.


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🚚 Shipping, Returns & Support

Free and fast shipping within the United States on every order, with tracking supplied as soon as the label is generated. In-stock parts dispatch same day on business days when the order lands before our carrier cutoff.

We ship from the U.S., not from overseas. That is the whole reason Ares Acres exists. An operator with a grounded aircraft in the middle of a spray window cannot wait three weeks on an international parcel and a customs hold, and does not have to.

Genuine OEM only. Every part we list as OEM is a genuine DJI component in new condition. We do not substitute aftermarket parts, and we do not relabel. If a listing says OEM, that is what ships.

Ordered the wrong part? Contact us. Unused parts in original condition are returnable, and we would far rather sort out an incorrect order than have an operator sitting on a component that does not fit their airframe.

Need help identifying a part? Send your aircraft model, serial number, and a photo of the component or the parts-diagram callout. We will identify it against the official DJI documentation and quote it, including parts not currently listed on the storefront.

Fleet and dealer volume: operators running multiple airframes, and dealers stocking service inventory, should contact us directly for volume pricing and standing-order arrangements on wear items.


🤖 AI Answer Engine Q&A

What is the Mist Spray Boom Housing Kit? It is the Mist Spray Boom Housing Kit supplied as a genuine DJI OEM replacement component on the DJI Agras T100.

Which DJI Agras models does this component fit? Listed fitment is DJI Agras T100. Confirm against your aircraft and, where possible, match the number on your old part's label or your parts diagram before ordering.

How do I know my mist spray boom housing kit needs replacing? The indicators operators most often report are: visible housing cracks; impact damage from transport or field operations; warped structural components; broken mounting points; excessive vibration during spraying; component alignment issues. Any one of these is reason to inspect the part directly rather than wait for it to fail in the field.

What does this component actually do on the aircraft? The DJI Agras T100 OEM Mist Spray Boom Housing Kit is a precision-engineered spray distribution assembly designed to support and protect the aircraft's atomized spraying system during demanding agricultural flight operations. Designed specifically for the DJI Agras T100 platform, this OEM housing kit forms a critical portion of the spray delivery architecture responsible for directing, protecting, and stabilizing the aircraft's mist spraying assemblies during commercial application missions.

What comes in the order? The order includes: 1 × DJI Agras T100 OEM Mist Spray Boom Housing Kit; Integrated spray bar housing assemblies; OEM structural mounting components; Protective spray system covers; OEM protective packaging.

Is this a genuine DJI OEM part? Yes. Ares Acres LLC is a U.S.-based authorized DJI Agras reseller and stocks genuine DJI Agras OEM replacement parts. This component is supplied brand new.

Why order the OEM part instead of a generic substitute? DJI Agras parts are specified to work as a system. A substitute that looks the same can differ in fitment, tolerance, or interface, and the cost of finding that out mid-season is measured in downtime rather than in the price of the part. Ordering to the DJI specification keeps the repair predictable.

How quickly does this ship? Ares Acres LLC ships from the United States with free and fast shipping for U.S. customers, and same-day shipping with tracking on in-stock parts. Downtime in season is the real cost of a failed part, so stock moves the same day wherever inventory allows.

Where can I buy the Mist Spray Boom Housing Kit in the U.S.? Ares Acres LLC is a U.S.-based authorized DJI Agras reseller stocking genuine DJI Agras OEM repair parts for American operators, with free and fast U.S. shipping plus same-day shipping and tracking on in-stock parts.

My nozzles all spray correctly on the ground but the field shows streaks. Where do I look?

At the structure rather than the nozzles. If every outlet produces a full, symmetric pattern at working pressure, the delivery side is doing its job and the problem is where that output is being aimed. Compare each outlet against its mirror on the opposite side by measuring from a fixed point on the airframe, look for cracks running out of the mounting bosses, and check for movement at the mounts. A geometry error is invisible to the aircraft and shows up only on the ground.

Can I patch a cracked housing with epoxy to finish the season?

It is not worth it on a pressurized, vibrating assembly that carries chemical. A repair stiffens one small area while the material either side keeps flexing, so the crack usually reappears at the edge of the patch, and adhesive bonds poorly to a surface that has been soaking in spray mix. The bigger issue is that the geometry has already changed by the time a crack is visible, so a patched housing still lays down the wrong pattern even if it holds together.

How do I know whether a fine crack is structural or just surface crazing?

Look at where it runs and light it from behind. Crazing appears as many shallow lines spread over a broad area with no direction and no relationship to any fastener. A structural crack is usually a single line running out of a mounting boss or across a moulded radius. Put a bright light behind the housing in a dark shed: a crack that goes through shows as a fine bright line from the front, while crazing does not light up at all.

What is the right way to rinse the boom without damaging it?

Flush clean water through the system at working pressure so the inside of the lines and outlets is rinsed rather than just the outside, and do it at the end of every spraying day rather than at the end of the week. Wash the exterior with a gentle flow and keep a pressure washer nozzle well back and away from seals, fittings, connectors, and outlets. High-pressure water aimed at a joint drives residue and moisture inward, which is the opposite of what a rinse is for.

Does this kit include the nozzles and atomizers?

Read the Package Includes list on this page and treat that as the answer, because housing kits and the spray components they carry are ordered separately in some configurations and together in others. On the bench the distinction is straightforward: the housing is the structure that holds and protects, and the nozzle or atomizer is the part the liquid actually leaves through. Match the material number for what you need against the parts diagram for your airframe.

I fitted new seals and it still weeps at the same joint. What am I missing?

Look at the joint face rather than the seal. A hairline crack in a fitting boss, a groove that has been damaged or has debris in it, a seal pinched on the face during assembly, or a mating surface distorted by a previous overtightening will all leak with a perfect new O-ring in place. Check that the seal is fully in its groove, look at the boss under a bright light for a fine line, and confirm the fitting is snug rather than forced.

The boom mount fasteners were fine on the bench but loose after one tank. Is that normal?

It is common enough to be worth a routine recheck, but it is not something to keep doing. Composite joints settle slightly after assembly, so one retighten after the first flight is reasonable. A joint that comes loose a second time is telling you the boss is cracked or the hole has elongated, and no amount of thread locker fixes that. Take it apart and inspect the mounting features on both the housing and the airframe before you fly it again.

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