fabbing a fuel tank

[fyresq]

Been entertaining the thought of fabbing a new fuel tank since the 16 gallons doesn't seem to be enough for the nevada backcountry and it just so happens that I took my stocker (71) tank out to do some body repair and noticed it's been brazed in three different places , two of the spot being on the bottom where some rust is. I have access to both steel and aluminum and brakes and rollers, etc. in a big machine shop. I can weld and have a 220 mig but I have a close friend who is a certified pressurized gas pipe welder that I can have burn it for me using his TIG.

I really like the MAF Aussie tank design but $850 plus the ride from AUS is a little extreme to me So I'm looking to build a 26+ gallon in cab fuel cell that sits under the drivers and passenger seats. I don't really want to put a between the frame one in because of future 4-link and v8 with dual exhaust, so I think I'll quickly run out of room in the tail.

Anyone build a similar one on here? Have general plans? Steel or aluminum? besides weight issues, which one is stronger for safety reasons? Really interested in sump pickup. More than one for extreme angles? Any venting or vapor locking issues? Baffles ideas (straight up, x-design, holes drilled thru the bottom, how high?)

Sorry for the twelve hundred questions, but's there's such a wealth of info on here..........

 

[Mace]

lookup dahondagods build..

I'll get the link later.

 

[DHONDAGOD]

My buildup on pirate, Cruiser section in the stickey at the top. Somewhere around page 5 I think. Mine wound up just over 26 gallons. Its nice not carrying gas cans anymore.


Make the prototype out of cardboard and packing tape. It makes it easier to duplicate later when your making it out of metal $$$$


Chris

 

[Mace]

Fryes, you going to make it yourself or pay someone to make it?

 

[fyresq]

Gonna fab it myself, tack it how I want it and have a cert pressure gas pipe welder burn it for me to make sure the welds are safe and sound. He told me he's a lot better at steel though and suggested using it, but I had been leaning towards aluminum which I see is what dhondagod did with his. I just know a steel one would be easier but.............I suck at aluminum and don't really have the right gun (altohugh my welder will do aluminum).

Dhondagod - Great tip on the cardboard. how did you setup your baffles, pickup tube etc. I like the sump idea but don't really want to cut the floor pan cause it's pretty clean. Any pickup problems on angle? Did you just use one pickup? And most important......my cruiser has about 9 gas lines that went to vapor tanks behind the front middle seat and the rear passenger corner. Did you just take all this out?

Thanx for the help

 

[DHONDAGOD]

My baffels are "half-height" inside the tank from the floor but angled 45deg to the pass side where the sump is. fuel pump draws from the bottom of the sump, no pickup tube. Dont try to over-engineer the baffles to keep the fuel from sloshing as it dosent take much. Gas guage dosent care so dont get carried away. As far as vents go, mine only has one vent line fitting that is routed outside the tank so no matter what angle (upside down, on either side etc) I can only lose less than a cup of gas. filler tube extends all the way down to the bottom of the tank on the opposite side it enters on as well for this reason also. I tried to design in as much spill protection into mine as I could.
I have only run out of fuel once due to extreme angle and that was pitched over heavy on the drivers side for several minutes on the exit waterfall of Wrecking Ball at JV. I got into the hole and couldnt get to rig to drive out. (nose was pointing to the sky and I was laying on the drivers side of the rig) Probley good cause I have no idea what my oil pressure was doing at that point. (no guage)

As far as steel vs. alum goes, Id say it depends on the time-frame. You could always make the first out of steel as it sounds like this would be easier for you right now. Dont try to learn alum welding on a gas tank. Once you have a working prototype you can make corrections/adjustments when you make the alum one. Trust me you can ALWAYS sell the steel one once your done.


Mace's was fun because he insisted using an in-tank pump. His came out nice I think. (just dont tell him his mufflers full of glitter)

PM me with a phone number if I can answer any other Q's for you.

Chris

 

[fyresq]

You guys are awesome. I hope you don't mind Dhondagod but I think I'll pretty much copy your design. Two more questions and I'll leave you alone. In looking at your write-up, it seems the sump hangs down a little - did you protect this in any way or is it a non-issue and where did you get your fuel pump?

 

[DHONDAGOD]

Yes my sump hangs down right next to the pass frame rail. Ive hit it a couple times (has nice long dents in it) but so far its fine. The plan was to add boat-side skids to protect it as well as aid in sliding off the rocks but well, that hasnt happened yet.


Chris

 

[megolfer]

Chris your tank looks really nice. I am thinking of doing th same as mine. Did you do the welding yorself. I wish I could weld aluminum, but never had access to a tig to learn on. I can mig really good. What was the estimate cost of yours.

Thanks
Cacy

 

[fyresq]

seems like a guy like dhondagod could make a few of these for select people for some $$$

 

[DHONDAGOD]

Casey, yes I welded mine and Maces. I have a 310amp Miller Tig at home that I use. On mine I used alot of favors up with a friend who runs his families A/C company. They have one of the larger sheet metal shop here in town. We spent one late night down there sheering/braking the alum for mine. (I had cardboard patterns)

On Mace's I had to rely on another friend to sheer and brake the alum who works for another company.

If I had a sheer and brake at home I would probley make a couple for $$$ but I just dont have the equip.

If you ever need anything alum welded Id be happy to help you if I can. Just let me know.

I have Solid Works now and am trying to learn that so I can do more "virtual building" of stuff and have exact measurements that can be emailed or printed to try to get stuff done faster.

(Yea I could have bought a sheer and brake for the cost of the software but it dosent take up any room in my garage and I can do more with it)

Build your tank out of cardboard and take it to an A/C sheetmetal shop and have them do the cuts and bends and Ill weld it up for you. Come by and take some measurements off mine if you want.

Hope you guys had a great Thanksgiving!

Chris

 

[DHONDAGOD]

Fyresq, depending on how big a hurry your in, send me a cardboard pattern and Ill see how long it would take to get made up. May take a month or better though. (I have a few things going right now)

Im sure we can find it a ride back to Tahoe when its done

Chris

 

[fyresq]

How about a tank with your same dimensions without the sump? I have an idea to put the sump inside the frame rail if I can find the room for a little more protection. So that would just be a flat plate on the bottom and I could fab and have someone weld the sump once I figure it out. I’m seriously interested – name a price ;p

 

[megolfer]

Thanks chris your your response. I just found out that a guy I know has access to s shear, break and is a professional welder. He said that he could make a nice one out of stainless becuse he has a couple of sheets laying around. Might see what he can do for me.