Sylvie Willis
Building an aluminium fuel tank is a challenging but rewarding endeavour. It requires careful planning, taking precise measurements, and selecting the right materials and tools. The process involves creating a prototype, cutting and welding aluminium sheets, and ensuring fuel tightness. One of the critical aspects is addressing tank slosh by incorporating fuel tank dividers or using fuel-resistant foam to stabilise the fuel and prevent it from starving the fuel pump during acceleration or cornering. While welding aluminium can be difficult, it offers the advantage of a natural aluminium finish and superior resistance to corrosion compared to steel.
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What You'll Learn
Measure the space where you plan to place the tank
Building a custom aluminium fuel tank can be a challenging but rewarding endeavour. Before you start, it is crucial to carefully measure the space where you plan to place the tank. This step is time-consuming but essential to ensure a proper fit for your fuel tank.
First, grab a piece of paper and a pencil. Draw a rough sketch of your intended fuel tank design, and as you do so, take multiple measurements of the space where the tank will be placed. Consider the overall dimensions of the space, including the height, width, and length. Additionally, keep in mind any specific features or requirements of the space that may impact the design of your fuel tank.
For instance, you need to allocate space for essential components such as fuel pick-ups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. Ensure you position the tank away from the direct heat of the exhaust, or plan to incorporate heat shielding to protect the tank. These considerations will influence the shape and size of your fuel tank, so it is important to account for them during the measurement process.
Once you have thoroughly measured the space and considered the necessary components, you can finalise your fuel tank design. At this stage, it is wise to create a prototype or mock-up of your tank to ensure it fits the allocated space and accommodates all the required components. A prototype will allow you to identify any potential issues or adjustments needed before finalising the design and beginning construction.
By taking the time to carefully measure and plan, you can ensure that your custom aluminium fuel tank will be well-suited to its intended space and function effectively.
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Choose the material and cut it to size
Aluminium is a popular choice for building a fuel tank because it is about 33% lighter than steel of equal strength and is highly resistant to corrosion due to the oxidation layer that develops on exposed aluminium. However, aluminium is incredibly difficult to weld and most fabricators choose not to use it for this reason. If you lack the ability to weld aluminium, you can opt for stainless steel, which is also highly resistant to corrosion and not too difficult to weld. Mild steel is another option, but it is corrosive, so you will need to factor in the cost of purchasing coatings.
Once you have chosen your material, you will need to cut it to size. Take measurements of the space where you plan to place your fuel tank, keeping in mind that you will need to accommodate fuel pick-ups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. It is recommended to draw your design on paper while taking measurements.
When cutting your aluminium, it is important to cut your pieces about 0.200 inches short of the actual tank dimensions. This will create a channel for the weld metal to lay in and help seal the seams. You can use a skill saw with a 40-50 teeth carbide blade to cut sheet metal. Alternatively, a band saw or jigsaw can be used to cut aluminium, with the latter being useful if you want a polished finish as it creates a welded edge that is easy to polish.
If you are using steel, you can cut it to size using a shear or a hydraulic finger brake. For aluminium, you can also use a shear if it is rated for the thickness of the aluminium you are using.
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Decide how to deal with tank slosh
Tank slosh is a serious hazard in various industries and modes of transportation. It is the transient movement of liquids within a confined container or tank. This can cause a shift in weight distribution, making a vehicle more difficult to control and potentially leading to accidents and injuries. Therefore, it is important to take preventative measures to avoid tank slosh and ensure the safety of operations.
One method to prevent tank slosh is the use of baffles. Baffles are vertical plates or barriers installed within the tank to reduce the free surface of the liquid. This helps stabilize the tank by reducing the amount of liquid that can slosh around. The design and placement of baffles within the tank are crucial to their effectiveness. They should be positioned to disrupt the natural sloshing frequencies of the liquid and sufficiently spaced to allow the liquid to flow through without causing turbulence.
Another technique to reduce sloshing is to introduce a gas layer or foam on top of the liquid, which is particularly effective for tanks carrying volatile substances. Additionally, pressurizing the tanks can make it harder for the liquid to move freely. Filling the tanks with floating ballast balls can also help prevent sloshing by increasing surface tension and forcing the liquid towards the bottom of the tank.
In the design of propellant systems, baffles or other structures can be incorporated inside the tank to disrupt the sloshing motion of the fluid. Software can also be utilized to control the direction of the vehicle and avoid moving at frequencies that excite the sloshing mode.
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Assemble the tank with welding or riveting
Aluminium is a great material for building a fuel tank due to its resistance to corrosion and its light weight. However, it is difficult to weld, and many fabricators choose to avoid it. If you are set on using aluminium, it is recommended that you construct the fuel tank and then take it to a local welder to weld it for you.
Before you begin assembling your tank, you must take measurements of the space where you plan to place it. This process is time-consuming, so it is recommended to draw your design on paper while taking the measurements. You must also consider the space needed for fuel pickups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. It is important to place the tank in an area where the exhaust won't cook it, and to build some heat shielding around the chosen area.
Once you have finalised your design, you can create a prototype to ensure that your final product will fit and that there is nothing missing in the design. You can cut your aluminium pieces using a skill saw with a 40-50 teeth carbide blade. Make sure everything is clamped down before cutting.
If you are welding your tank, you must decide whether to weld the pieces together or to use a combination of welding and riveting. Pop rivets can be tricky to weld over, and they can make the work more difficult for the welder. Clecos are recommended over pop rivets as they can be easily welded over.
If you are using rivets, you can put the tank together with aircraft rivets (AN470AD-4) with a spacing of approximately 5/8". Close spacing for rivets is important to obtain tight seams that will be leak-proof once sealed with a fuel-proof sealing compound.
If you are welding, you must tack the pieces up every inch or inch and a half before welding up the seams. If you do not do this, the thin aluminium plate may warp easily from the torch heat. Cut your pieces so that they are about .200 inches short of the actual tank dimensions to create a channel for the weld metal to lay in and to help seal the seams.
After welding, you must pressure test the tank using air and 10-15 psi. Look and listen for leaks and spray all the seams with diluted dish soap—the soap will bubble if there is a pinhole leak.
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Test the tank for leaks
Testing your aluminium fuel tank for leaks is an important step in ensuring the safety and longevity of your tank. Here is a step-by-step guide on how to do it:
Prepare the Tank:
Firstly, decide whether you want to test the tank while it is still installed or after removing it. If the tank is old and has been exposed to seawater or high humidity, it may be best to remove it for a thorough inspection. Drain the fuel from the tank if you plan to take it out. If you choose to test it while it's still installed, make sure to seal all fittings and close the valve to prevent any fuel leakage during the test.
Choose a Testing Method:
There are two main methods for testing aluminium fuel tanks for leaks: pressure testing and liquid penetrant testing. Pressure testing involves pressurizing the tank with air or water and looking for leaks. This method can be effective, but it should be done with caution as it can put a lot of force on the tank, and small pinhole leaks may be difficult to detect. Liquid penetrant testing, on the other hand, is a simpler and cheaper method that can accurately detect even small pinhole leaks.
Pressure Testing:
If you choose to pressure test your tank, use a pressure that is safe for your tank. Do not exceed 25 psig for aluminium tanks. You can use air and apply 10-15 psi, or you can fill the tank with water and apply 25 psig. Look and listen carefully for any leaks, and use soapy water to help detect pinhole leaks. Spray soapy water on the seams and fittings and look for bubbles. This will indicate the presence of a leak.
Liquid Penetrant Testing:
If you prefer a simpler and less risky method, try liquid penetrant testing. Go to a weld supplier and purchase a can of liquid penetrant and a can of developer. Follow the instructions on the can for application. The developer will draw the penetrant back out of the cracks, and you can interpret the results to understand the depth and location of any leaks. This method is accurate and will help you identify and fix potential issues before they turn into leaks.
Interpret Results and Make Repairs:
Whether you choose pressure testing or liquid penetrant testing, carefully interpret the results to locate any leaks or potential weak spots. Small pinhole leaks can be "sealed" by punching them with a hammer and punch, but this may not be a permanent solution. Consider installing a new tank if the leaks are significant or if the tank is old and corroded. Proper installation, ventilation, and a dry location are key to extending the life of your aluminium fuel tank.
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Frequently asked questions
Start by taking measurements of the space where you plan to place your fuel tank. Consider the space you’d need for any fuel pick-ups, filler, vents, level sensors, mounting straps, and lines. Once you have your measurements, create a prototype.
You will need aluminum, a skill saw, a carbide blade, and a shear. The type of aluminum and its thickness will depend on your specific use case.
One of the most common issues with aluminum fuel tanks is welding. Aluminum is incredibly difficult to weld, and many fabricators have given up using it because of this. If you are not confident in your welding abilities, consider taking your cut-out pieces to a local welder.
Tank slosh is when the fuel moves around in the tank when going around a corner or accelerating. This can starve the fuel pump of fuel. To prevent this, you can stuff the tank with fuel-resistant foam or build a fuel sump.
