Ameer Randolph
Building a fiberglass fuel tank is not a beginner project. It requires some basic fiberglass skills and knowledge of which materials to use. For instance, it is important to use a resin that is fuel-proof, as most are not. Some methods involve using a foam board, coating it with fiberglass, and then pouring in gas to dissolve the foam. Other methods include cold molding, where sheets of glass are cut to size and put together to build a tank.
| Characteristics | Values |
|---|---|
| Materials | Fiberglass, resin, epoxy, aluminium, steel, cloth, glass beads, flox, putty, wax, body putty, vinylester resins, polyester resin, glass sheets, duct tape, masonite, styrofoam, acetone, sloshing compound, fiberglass bidirectional cloth, epoxy resin, fuel-resistant epoxy, glass |
| Techniques | Cold molding, cutting, welding, glasswork, smoothing, sanding, coating, sealing, layering, pouring, drilling, gas welding, TIG welding |
| Challenges | Resin selection, sealing, air bubbles, leaks, cost, weight, capacity, frustration, time, corrosion, fuel-proofing, damage |
| Tips | Use a pre-built panel, use a fuel-proof resin, use epoxy sealer, use Caswell sealer, use a dremel tool, use approved resin, use fuel-resistant epoxy, use a slurry of resin and flox, use a large work surface, use a foam board, use a plastic drum, use aluminium tanks, use a core, use a mold, use a liner |
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What You'll Learn
Choosing the right resin
When choosing the right resin for a fibreglass fuel tank, it is important to consider the type of fuel that the tank will be holding. For example, for a kerosene fuel tank, epoxy resin is recommended. Specifically, the West System 105 resin and 209 extra slow hardener have been used with good results.
If you are looking for a gasoline-safe fibreglass resin, there are a few options to consider. Firstly, it is important to note that the curing agent for fuel contact needs to be an aromatic amine, such as EZ POXY 87 hardener, which can be purchased from ACS. This hardener is to be used in conjunction with Ez Poxy resin. Another option for a gasoline-safe resin is T-88, an aircraft structural adhesive that is "unaffected" by gasoline.
It is worth noting that some sources suggest that polyester resin is not suitable for gasoline applications. However, other sources recommend polyester or vinyl-ester resin for repairing fuel drains. Bondo resin, which can be found at auto parts stores, is one option that has been suggested.
For diesel fuel tanks, an ISO PE or VE resin is likely to be suitable. However, it is important to consider the different properties of these resins and to wax the last coat of resin to prevent the diesel fuel from picking up the uncured surface.
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Sealing and testing for leaks
Sealing a fibreglass fuel tank is a crucial step in its construction, and there are various methods to achieve this. One common approach is to use an epoxy sealer, which is often considered the best option for fibreglass tanks. It is essential to ensure that the resin used is fuel-proof, as most resins are not. Auto gas, in particular, can be corrosive and eat away at resins that were previously believed to be fuel-proof. To avoid this, it is recommended to use a fuel-resistant epoxy, especially one that is alcohol-resistant, as this may be the future of Mogas.
Another method for sealing a fibreglass fuel tank is to use a coating or liner. One product mentioned is Caswell, which is said to be compatible with fibreglass. Additionally, some people use a paste wax or Saran Wrap to protect the tank's interior. It is worth noting that sealing a fibreglass fuel tank can be expensive, and some people opt to make metal tanks instead, as they can be more cost-effective and less prone to leakage.
Testing for leaks is vital to ensure the safety and effectiveness of a fibreglass fuel tank. One method is to use air pressure to test for leaks, but this must be done with caution, as too much pressure can blow the seams apart, creating a mess. A more common approach is to fill the tank with fuel and let it sit for several weeks to observe any leaks. This method allows for the identification of potential issues with the sealer before finishing the surface.
It is important to note that building a fibreglass fuel tank is not a beginner's project and requires careful planning and execution to ensure safety. Working with fuel and resins can be dangerous, so it is always recommended to consult professionals when dealing with potentially hazardous materials and processes.
Overall, sealing and testing for leaks in a fibreglass fuel tank are crucial steps that require careful consideration and attention to detail. By using the appropriate sealing methods and thorough leak testing, a safe and effective fibreglass fuel tank can be constructed. However, it is essential to weigh the benefits of a fibreglass tank against other options, such as metal tanks, to make an informed decision based on one's specific needs and capabilities.
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Using a core or cold moulding
One user recommends creating a simple rectangular female mould out of cardboard and duct tape, braced with timber. Line the mould with sheet plastic and spray it with a silicon lubricant for release. Another user suggests making a mould inside the hull of the boat to maximise space.
Once you have your mould, lay up your fibreglass sheets, then cut them to size. Assemble the sheets to build your tank, using putty fillets in the corners and tabs to hold the sheets together. You can also use a slurry of resin and flox to bond the pieces together.
When using a core, such as Divinycell, you would typically use fibreglass inside and out to create the tank shape, leaving an opening for the top, which can be made separately and then stuck together.
It is important to note that some users have expressed concerns about the safety of fibreglass fuel tanks, especially regarding ethanol-based fuels. It is recommended to use a suitable resin that is fuel-resistant, such as epoxy or polyester resin, and to coat the inside of the tank with a fuel-resistant sealer.
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Smoothing and finishing the surface
Start by sanding the shell of the tank. Use a fine-grit sandpaper, such as 180- or 220-grit, to smooth out any rough areas and create a uniform surface. Pay close attention to the corners and edges, as these areas might require more sanding to achieve a smooth finish. It is important to wear suitable protection, such as a respirator, to avoid inhaling any dust particles during this process.
Next, apply a fibreglass gel coat to the entire surface of the tank. This step will help fill in any minor imperfections and create a smooth base for the final finish. Follow the manufacturer's instructions for mixing and applying the gel coat, ensuring proper ventilation during application. Allow the gel coat to cure completely according to the product's specifications.
Once the gel coat has cured, inspect the surface for any remaining imperfections or small holes. Use a body putty or automotive filler to fill in these areas, following the manufacturer's instructions. Sand the putty or filler once it has cured to ensure a seamless blend with the surrounding gel coat.
Finally, apply a finish coat to the tank. This could be another layer of gel coat or a specialised automotive paint, depending on your preference and the intended use of the fuel tank. Ensure that the product you choose is compatible with fibreglass and fuel types. Follow the manufacturer's instructions for proper application, including recommended drying or curing times.
Throughout the smoothing and finishing process, it is essential to work in a well-ventilated area and to follow all safety precautions when working with chemicals and power tools. By taking your time and carefully executing each step, you can achieve a smooth and professional finish on your fibreglass fuel tank.
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Adding petcocks and fuel caps
Planning:
Before you begin, it is important to select the appropriate location for the petcocks and fuel caps. Mark the exact spots where you will be installing them. Ensure you have the correct type and size of petcocks and fuel caps for your specific fuel tank.
Cutting the Holes:
Using a suitable cutting tool, carefully cut holes at the marked spots. The holes should be slightly larger than the diameter of the petcocks and fuel caps to ensure a snug fit. A Dremel tool can be useful for this step, as it allows for precise cutting.
Installing the Petcocks:
After cutting the holes, it is time to install the petcocks. If you are using threaded petcocks, ensure that the threads match the size of the holes and screw them into place securely. If your petcocks are not threaded, you may need to use an adhesive or sealant suitable for fuel tank applications to ensure a tight seal.
Fuel Cap Installation:
For fuel caps, you may need to consider additional components such as a fuel neck. The fuel neck should be securely attached to the fuel cap, ensuring a tight fit to prevent leaks. Once the fuel neck is in place, you can attach the fuel cap according to its specific installation requirements.
Sealing and Testing:
After installing the petcocks and fuel caps, it is crucial to seal the connections to prevent leaks. Use a suitable sealant or adhesive that is compatible with the fuel type you will be using. Allow the sealant to cure completely according to the manufacturer's instructions. Once cured, you can fill the tank with fuel and test for any leaks by observing if there is any fuel seepage around the petcocks and fuel cap connections.
Final Steps:
If no leaks are detected, your fibreglass fuel tank with installed petcocks and fuel caps is ready for use. However, it is always recommended to perform a final surface finish to ensure the longevity of the tank. Sanding, smoothing, and applying a suitable coating can enhance the durability and aesthetic appeal of your fuel tank.
Remember to follow safety precautions when working with fuel tanks and always consult a professional if you are unsure about any steps or materials.
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Frequently asked questions
There are several ways to build a fiberglass fuel tank. One method is to use a foam board that melts in the presence of gas. First, coat the foam with fiberglass. Then, cut a hole in the fiberglass and pour in gas. The gas will melt the foam, and you can pour the residue out, leaving you with a tank.
You will need a foam board, fiberglass, and epoxy resin. You will also need to ensure that the resin is fuel-proof, as most are not.
First, cut the foam board into the desired shape. Then, stick the fittings for the outlet and gas cap into the board. Next, cover the entire thing with fiberglass matt and epoxy resin. After curing, pour acetone into the gas cap opening to dissolve the foam.
One common mistake is not using a fuel-proof resin. Some homebuilt aircraft have found this out the hard way, as aircraft fuel can eat through many resins. Another mistake is not properly sealing the tank, which can lead to fuel leaks.
