Sylvie Willis
Building a fuel tank can be a challenging task, but with careful planning and execution, it is certainly achievable. The first step is to take precise measurements of the space where the fuel tank will be placed, considering any necessary components such as fuel pick-ups, vents, and mounting straps. The choice of material is crucial, with options including mild steel, stainless steel, and aluminum, each offering advantages and disadvantages in terms of corrosion resistance, weight, and weldability. Constructing a prototype, such as a cardboard model, is recommended before finalizing the design. Once the design is confirmed, the fabrication process involves bending and welding the metal, ensuring a tight fit-up and sealing the welds with aircraft sealant or epoxy coating to prevent leaks and corrosion. Baffles or dividers may be added to reduce fuel slosh and maintain balance, especially for larger tanks. Testing and inspection are then performed to ensure the fuel tank's functionality and safety.
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What You'll Learn
- Use steel to build the tank and coat it with a fuel tank-specific gel/epoxy to make it rustproof
- Test for leaks with air and water
- Use aircraft sealant to seal the welds
- Baffles strengthen a large tank and reduce sloshing
- Position the fuel pump at the bottom of the tank with angled blocks to ensure liquid flows into it
Use steel to build the tank and coat it with a fuel tank-specific gel/epoxy to make it rustproof
Building a fuel tank from steel involves several steps, and it's important to ensure your tank is rustproof to maintain its longevity.
Firstly, you'll need to decide on the thickness of the steel you'll use. For a 25-gallon tank, you might use .120 for the top and sides and .188 for the bottom, which can also serve as a skid. You'll then need to cut and weld the steel to your desired shape and size, ensuring you use the appropriate welding method for the job—TIG welding, for example, is preferable to MIG as it doesn't leave pin holes.
Once you've fabricated your steel tank, you'll need to make it rustproof. One way to do this is to use a fuel tank-specific gel or epoxy coating. This process usually involves two steps. First, you'll need to etch the interior of the steel tank with an acid component, which is typically provided with the coating. After that, pour the coating into the tank and rotate it to ensure all sides are thoroughly coated. Pour out any excess and let it dry in a sunny spot for a couple of days.
There are other ways to prevent rust in your fuel tank. Some people recommend using white vinegar to treat rust, and there are also tank liners available, though these may fail in the presence of fuels containing ethanol and other additives. If you're using modern fuel, be aware that it often contains ethanol, which will promote corrosion over time. To seal the welds in your tank, you can use aircraft sealant, but be careful not to seal any screens you want to keep open.
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Test for leaks with air and water
Testing a fuel tank for leaks with air and water is a common method to ensure the tank's integrity. However, it is important to note that the viscosity of water is different from that of fuel, and while a tank may hold water, it does not guarantee that it will hold fuel. Nevertheless, water leak tests can be useful for identifying gross leaks before installing components like baffles or bulkheads.
One method for testing with air and water is to fill the tank with water and then pressurize it with air. This can be done by connecting the tank to a pressurized air volume of about 1 cubic foot and pressurizing it to 15 PSI. A pressure gauge is attached, and the pressure is monitored for any drops. The amount of water loss can be calculated using gas laws, and if the water holds, it indicates that the tank will likely hold fuel since fuel has a greater viscosity.
Another method is to use a balloon. All openings in the tank are wrapped with tape, except for two small ones. A balloon is attached to one of the openings, and air is pumped into the tank until the balloon rises. At this point, a soapy water solution is sprayed onto the outside of the tank to check for leaks.
It is important to be cautious when testing with air pressure, as too much pressure can deform or even explode the tank. Additionally, some sources suggest using a tracer gas such as helium or hydrogen for more accurate results, as these gases can identify smaller holes.
While water leak tests can be useful for identifying major leaks, they may not detect smaller holes that could result in fuel leaks. Diesel, for example, has a lower surface tension than water and will find pinholes that water might not. Therefore, it is recommended to combine water testing with air pressure testing and to be cautious when interpreting the results.
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Use aircraft sealant to seal the welds
When building a fuel tank, it is important to seal the welds to prevent fuel leaks. One way to do this is by using aircraft sealant. Aircraft sealants are glues or adhesives designed to create airtight seals in the rivets, joints, and other parts of fuel tanks. They are made to withstand extreme pressure, temperature, and vibrations.
To seal the welds in your fuel tank, start by testing for leaks with air and water. Fill the tank with water and apply 1.5-2 psi of air to locate any leaks. Once you have found and addressed any leaks, drain the water, let the tank dry, and prepare the tank for sealing. Clean the welds and ensure they are free of any previous sealants, using an aircraft fuel tank sealant remover if necessary.
Next, apply the aircraft sealant to the welds, following the instructions and safety guidelines provided with your chosen product. Ensure you do not have any screens or areas you do not want to be sealed, as the sealant will bond to any surface it touches. Allow the sealant to cure completely before refilling the tank with fuel.
It is important to select a high-quality aircraft sealant that meets industry standards and regulations, such as FAA regulations for aircraft fuel tank sealants. These approved sealants, known as PMA products, are designed to work interchangeably with Original Equipment Manufacturer parts and meet the same regulatory standards.
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Baffles strengthen a large tank and reduce sloshing
When building a fuel tank, it is important to consider the function of baffles. Baffles are a crucial component that strengthens large tanks and significantly reduces sloshing. Sloshing refers to the movement of fuel within the tank during manoeuvring, which can cause a shift in the centre of gravity and lead to unwanted dynamics.
Baffles are structures welded inside the fuel tank that act as reinforcements, providing stability and reducing the fuel's movement. They help keep the fuel steady during sudden movements, such as rapid acceleration or pitch-up climbs, preventing the fuel from rushing backwards and affecting the aircraft's flight path.
In addition to baffles, some combat aircraft use a coarse, sponge-like foam that occupies a small percentage of the tank's volume. This foam effectively dampens fuel oscillations, ensuring a smoother flight. However, it is important to note that regular foam is not recommended due to its tendency to crumble over time and plug up essential components.
When incorporating baffles into the design, it is essential to consider the thickness of the tank material. For instance, when constructing a 25-gallon auxiliary tank, the top and sides may use a thickness of .120, while the bottom, which also serves as a skid, may require a thicker gauge, such as .188.
By utilising baffles in the construction of a fuel tank, you can enhance the overall strength of the tank while minimising fuel sloshing, resulting in improved performance and safety. This makes baffles an essential consideration when designing and fabricating fuel tanks, particularly for aircraft and other vehicles that experience rapid manoeuvring.
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Position the fuel pump at the bottom of the tank with angled blocks to ensure liquid flows into it
To make a fuel tank, one of the crucial steps is positioning the fuel pump at the bottom of the tank to ensure efficient fuel extraction. Here are some detailed instructions for this process:
Firstly, it is important to understand the purpose of this setup. By placing the fuel pump at the bottom of the tank, you ensure that the engine can utilize as much fuel as possible. Without this placement, the engine may only be able to access a fraction of the fuel, such as 60% as mentioned by a user, due to negative pressure buildup. Additionally, having the pump at the bottom prevents the fuel from sloshing away from the pump as levels deplete, which could cause the engine to cut out.
Next, the use of angled blocks is essential to guide the liquid fuel towards the pump. This setup functions similarly to the plughole in a sink, where the angled surfaces direct the water towards the drain. By creating this funnel-like structure, you ensure that the fuel naturally flows towards the pump, regardless of the amount of fuel in the tank.
When constructing the angled blocks, it is important to consider the material and its compatibility with the fuel type. Some fuels, such as those with a high alcohol content, may react negatively with certain materials. For example, one user cautions against using foam in fuel tanks due to the potential for crumbling and blockage. Instead, consider using a fuel tank-specific gel or epoxy coating to seal your angled blocks and any other components that come into direct contact with the fuel.
Before installing the fuel pump and angled blocks, it is crucial to test for leaks. One method suggested by a user is to fill the tank with water and apply a small amount of pressure (PSI) to locate any leaks. It is important to note that the amount of pressure applied should be minimal to avoid potential explosions. Once the tank is confirmed to be leak-proof, it can be drained, dried, and prepared for installation.
Finally, during the installation process, ensure that the fuel pump is securely fastened at the bottom of the tank. Consider using straps instead of tabs for a more reliable fastening method. Additionally, include a gas relief valve connected to open air, as mentioned by a user, to further enhance the efficiency and safety of your fuel tank setup.
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Frequently asked questions
The first step is to take measurements of the space where the fuel tank will be placed. It is important to keep in mind that there needs to be space for fuel pick-ups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines.
Aluminium is a popular choice due to its resistance to corrosion, lightweight properties, and ease of forming. However, it is difficult to weld. Stainless steel is another option as it is highly resistant to corrosion and easier to weld than aluminium.
Sloshing can be prevented by dividing the tank into smaller sections or cells with trap doors or small holes between them. This ensures that the fuel pump pickup remains submerged and prevents a large amount of fuel from shifting weight and affecting the balance of the vehicle.
