Katerina Swanson
Aluminum is a popular material for fuel tanks due to its stability, ease of use, and ability to yield predictable results. However, welding aluminum can be challenging, and the thickness of the aluminum sheet used for fabrication is critical to ensuring the structural integrity of the tank. Various factors, such as the tank's intended use, capacity, and mounting method, influence the optimal thickness of aluminum for a fuel tank.
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What You'll Learn
Aluminum fuel tank thickness varies
In one instance, an individual welding an aluminum fuel tank for their Dakota pickup truck opted for 0.125-inch-thick aluminum checker plate. They mentioned that their shear was maxed at 0.100-inch thickness, which would have been the minimum thickness for that size of fuel tank. However, they chose to use 0.125-inch aluminum to ensure the tank was secure and minimize stress on the material.
Another individual building an aluminum fuel tank for a 56 Chevy Nomad Street Rod considered using 0.125-inch aluminum but decided on 0.100-inch thickness due to the limitations of their shear capacity. They planned to use 5052 aluminum, which is commonly used in the marine industry with a thickness of 1/8 inch (0.125 inches). This thickness is often considered the minimum for fuel tanks, depending on the support structure.
The type of alloy used can also impact the thickness of the aluminum fuel tank. For instance, one person mentioned using 0.090-inch-thick 5052 aluminum for an under-car fuel tank with an in-tank pump. They noted that using a different alloy, such as 6061, would result in cracking due to vibration. Additionally, the method of assembly, such as welding or riveting, can influence the thickness of the aluminum used.
When constructing an aluminum fuel tank, it is essential to consider factors such as the intended use, size, mounting method, and personal preferences. These factors will determine the appropriate thickness of the aluminum, ensuring the tank's durability and safety.
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Welding aluminum is difficult
Aluminium is a common type of metal used in fabrication. It is non-corrosive, lightweight, and aesthetically pleasing, making it a popular choice for a variety of applications. However, welding aluminium is considered difficult due to several factors.
Firstly, aluminium is a soft and highly sensitive metal. It is protected by a tough oxidized layer, which has a melting point approximately 2,500 degrees Fahrenheit higher than that of pure aluminium. This means that the oxide layer must be thoroughly cleaned from the metal before welding can begin, requiring high heat without burning holes in the aluminium underneath.
Secondly, aluminium's sensitivity makes it susceptible to impurities during the welding process. In its molten state, aluminium absorbs hydrogen, which can cause the metal to become porous and weak once it solidifies, leading to subpar welds. Contamination can also occur due to exposure to dirt, air, and water.
Additionally, welding aluminium can be challenging due to the difficulty in indicating weld progress and quality. The welding process itself can be messy and slow, especially with certain types of welding like TIG and stick welding. While TIG welding allows for a high level of precision and strong welds, it is one of the most difficult welding techniques to master and can be time-consuming.
Furthermore, the equipment required for aluminium welding can be expensive. A basic TIG welding setup costs around $750 to $1000, and additional consumables such as filler rods, shielding gas, and tungsten electrodes add to the overall cost. While MIG welding is considered easier to learn and quicker, it may require a special "gun" for aluminium wire, which incurs an extra expense.
Despite the challenges, welding aluminium can be achieved with practice and the right equipment. It is important to choose the appropriate welding technique and carefully control the heat to avoid burning the aluminium. With time and dedication, welders can master the skill of aluminium welding and take advantage of the metal's unique benefits.
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Aluminum is a stable, easy-to-work-with material
Aluminium is a stable, easy-to-work-with material. It is a popular choice for fuel tanks due to its lightweight yet sturdy nature. Aluminium is also a clean material, and its high thermal conductivity means it reaches its melting point very quickly. This can be advantageous for welding, but it also means that aluminium can suddenly puddle and collapse, leaving a gaping hole if the welder is not careful.
Aluminium is a good choice for fuel tanks as it is easy to form and readily available from homebuilt suppliers. The 5052 H32 aluminium alloy is a popular choice as it is very malleable and can be formed into various shapes. This alloy is also often used in the marine industry for fuel cells, with a thickness of 1/8" commonly used.
For a fuel tank with an in-tank pump, one might opt for a thickness of 0.090 5052 aluminium. This thickness is also suitable for mounting tabs, which can be made from the same material as the tank. For a larger fuel tank, a thickness of 0.100 is recommended as a minimum, and some have suggested using 0.125 aluminium for added strength.
When creating an aluminium fuel tank, it is important to consider the joining method. While welding is an option, it can be challenging and may require specialised equipment. Many opt for riveting instead, which can create a strong and leak-proof seal when combined with a good fuel-proof sealing compound.
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Aluminum tank build tips
Aluminum fuel tanks are a popular option for many vehicles, from boats to cars and even aircraft. Building your own aluminum tank is a complex process, but with the right tools and knowledge, it is achievable. Here are some tips to help guide you through the process of building your own aluminum fuel tank.
Firstly, it is important to determine the thickness of the aluminum you will use. The thickness will depend on the intended use of the tank and the amount of fuel it needs to carry. Common thicknesses range from 0.090 to 0.125 inches, with some tanks requiring thicknesses of 1/8 or 1/4 inch. Consider the size of your tank and the amount of fuel it will need to hold to choose an appropriate thickness.
When it comes to the type of aluminum, 5052 aluminum is a popular choice for fuel tanks. It is important to use a suitable welding method for this type of aluminum, such as TIG welding with 4043 3/32 rod and a Dynasty machine. Additionally, consider using a weldable flange to assemble the tank, which can be purchased or machined from weldable aluminum stock.
Before welding, it is crucial to tack the aluminum pieces in place to prevent warping. For thin plates, tack welding every inch or inch and a half is recommended. This will help create a channel for the weld metal and ensure tight seams. After welding, pressure test the tank at 10-15 psi and check for leaks using diluted dish soap, which will bubble if there are any pinhole leaks.
To simplify the construction process, build a rectangular cube frame from aluminum angle, and then attach the sheets to this frame. This will provide a sturdy base for your tank. Additionally, consider the mounting points for your tank, which can be made from square tubes, angles, or straps. Ensure that the mounting tabs are made from the same material as the tank and are thick enough to support the weight.
Lastly, remember to keep the design simple. Avoid odd shapes that will complicate fabrication and installation. Aim for a design that uses as few separate pieces of metal as possible to reduce the number of welded seams. By following these tips and guidelines, you can successfully build your own aluminum fuel tank.
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Aluminum tank mounting points
When it comes to mounting an aluminium fuel tank, there are several considerations to keep in mind. Firstly, the thickness of the aluminium material used for the tank is crucial. The standard thickness can vary depending on the specific application and intended use. For example, a custom fuel tank for a commercial boat may require a different thickness compared to a fuel tank for a car or motorcycle. It's important to choose an appropriate thickness to ensure the tank's durability and longevity.
Now, let's delve into the specifics of aluminium tank mounting points:
- Mounting Options: When mounting an aluminium fuel tank, you have several options for the mounting points themselves. You can choose between using square tubes, angles, straps, or mounting tabs. The choice depends on the specific design and requirements of your application. For instance, if you want a clean look for a car fuel tank, you might opt for a particular type of mounting point that blends seamlessly with the vehicle's design.
- Material Compatibility: It is important to consider the compatibility of the mounting point material with the aluminium fuel tank. Some sources suggest using the same material for the mounting tabs as the tank itself. This ensures that the mounting points can withstand similar stresses and vibrations as the tank. However, in certain cases, different materials may be used for mounting points, such as steel mounting brackets or clamps, which provide a secure and rust-free mounting option for aluminium fuel tanks.
- Mounting Techniques: The technique used to mount the fuel tank is also crucial. Welding is commonly employed to attach mounting tabs or to create a welded tab for grounding the fuel tank. Additionally, drilling and tapping may be necessary when creating mounting points, especially if you are using a plate or chassis-mounted pump. Ensuring tight connections and applying dielectric grease are also important considerations during the mounting process.
- Mounting Location: The location of the mounting points should be carefully considered. For example, in-tank mounting setups offer the advantage of easy access in case of failure without the need to drop the tank. On the other hand, under-car mounting setups may require a different approach to ensure a clean look and secure mounting.
- Weight Distribution: It is important to ensure that the mounting points are not solely responsible for supporting the entire weight of the fuel tank. Proper weight distribution is crucial for the stability and safety of the mounted tank. This consideration may influence the placement and design of the mounting points.
By carefully considering these aspects of aluminium tank mounting points, you can ensure a secure, functional, and aesthetically pleasing installation of your aluminium fuel tank.
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Frequently asked questions
The ideal thickness of aluminum for a fuel tank depends on the intended use and personal preference. Some common thicknesses used for fuel tanks range from 0.04" to 0.125" (0.100"-0.125" being the most popular).
5052 aluminum alloy is a popular choice for fuel tanks due to its ease of forming and availability.
Aluminum is a clean, stable, and easy-to-work-with material that provides predictable results. It is also lighter than fiberglass tanks of similar capacity.
Welding aluminum can be challenging due to its high thermal conductivity, which can lead to sudden puddling and collapse if not properly controlled. However, it is not impossible, and some people choose to weld their aluminum fuel tanks.
Instead of welding, you can use aircraft rivets (AN470AD-4) with close spacing (approximately 5/8") to assemble the tank. The seams and rivets must then be sealed with a fuel-proof compound to ensure leak-proof construction.
