Mercedes Mullins
Building a steel fuel tank is a complex process that requires careful planning and execution. It involves several steps, starting with measuring the space where the tank will be placed and determining its desired shape and dimensions. The tank can be made from six pieces of metal, but it is preferable to form the four largest parts from one piece of metal by bending three corners. This reduces the amount of welding required and results in a stronger and more aesthetically pleasing tank. The builder must then decide on the type of steel to use, considering factors such as corrosion resistance and welding difficulty. Stainless steel, for example, is highly resistant to corrosion and relatively easy to weld, while mild steel is more affordable but requires additional coatings to prevent corrosion. Once the materials are chosen, the builder needs to cut the metal to size, curl the edges, and weld the pieces together, ensuring a tight fit for a strong weld. Some builders choose to use a combination of welding and sealing methods, such as MIG welding and fuel tank sealers, to ensure a leak-free tank. Testing for leaks with pressurised air and soapy water is crucial before finalising the construction.
| Characteristics | Values |
|---|---|
| Materials | Steel, preferably stainless steel, or aluminum |
| Shape | Rectangular, with six sides, or any desired shape |
| Size | Customizable, depending on available space |
| Construction | Requires welding, sealing, and coating |
| Welding Techniques | MIG, TIG, or outsourcing to a professional welder |
| Sealing Techniques | Gas tank sealers, epoxy coatings, or soldering |
| Coating | Rust-proof coatings, acid etching, or PVC covering |
| Testing | Pressure testing with air and soapy water to check for leaks |
| Mounting | Mounted on a square tube or behind the seats |
| Ventilation | Vented or unvented cap with a rollover valve |
| Baffles | Welded inside to reduce "tank slosh" |
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What You'll Learn
Choosing the right material
Mild steel, for instance, is a readily available and affordable option. However, it is important to remember that mild steel is corrosive. This means that you will need to take additional steps during construction, such as coating the tank to prevent corrosion. The coating process can be tedious and requires careful application to ensure effectiveness. Unfortunately, coatings may not hold up well over time, and the added expense of purchasing coatings may outweigh the initial cost savings of choosing mild steel.
Stainless steel emerges as a more suitable alternative due to its high resistance to corrosion. It is only slightly more expensive than mild steel and eliminates the need for costly coatings. Stainless steel is also a good welding material, making it a convenient choice if you plan to weld your fuel tank.
Another popular option for fuel tank construction is aluminium. Aluminium is lightweight, about 33% lighter than steel of equal strength, making it ideal for fuel tanks to reduce the overall weight of the vehicle. Additionally, aluminium is highly resistant to corrosion due to the oxidation layer that forms on its surface. However, aluminium has one significant drawback—it is notoriously difficult to weld. Most fabricators opt to construct the fuel cell using aluminium and then take it to a specialist welder.
When deciding on the material for your steel fuel tank, consider factors such as corrosion resistance, weight, ease of welding, and cost. Stainless steel and aluminium stand out as excellent choices due to their unique properties, while mild steel may require more effort and expense to maintain over time.
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Preparing the steel
Steel is a common choice for building a fuel tank due to its durability and customizability. However, there are some important considerations to keep in mind when preparing the steel for your fuel tank project.
Firstly, it is essential to select the appropriate type of steel. Mild steel is commonly used, but it is crucial to remember that it is corrosive. If you choose mild steel, you will need to take additional steps in your construction process, such as coating the steel to prevent corrosion. Stainless steel is another option that is highly resistant to corrosion and relatively easy to weld. While it is more expensive than mild steel, the added cost of coatings for mild steel may offset this difference.
Once you have selected the type of steel, the next step is to prepare the surface. The steel should be clean and free of any contaminants, such as oil or rust, especially if it will be the interior of the tank. Chemical metal prep can be used to effectively remove any surface rust. It is important to note that coatings may not hold up well over time, so proper surface preparation is crucial.
When cutting the steel, it is recommended to use a skill saw with a 40-50 teeth carbide blade. Clamping down the material before cutting is essential for safety and accuracy. If you plan to weld the steel, it is beneficial to curl the edges of the joints before welding, as it ensures uniform corners and reduces distortion. A beading machine with Round-Over dies can be used for this purpose.
Before welding, it is essential to consider the design of your fuel tank. Building a fuel tank from six pieces of metal is possible, but it is preferable to make the four largest parts from a single piece of metal by bending three corners. This reduces the amount of welding required and results in a stronger and more aesthetically pleasing tank. Don Houseman, a talented metalsmith, demonstrates this technique by first measuring the space where the tank will go and determining the desired shape and dimensions.
In summary, preparing the steel for your fuel tank involves selecting the appropriate type of steel, thoroughly cleaning and preparing the surface, cutting and shaping the steel accurately, and considering the design of your tank to minimize welding and maximize strength. Following these steps will help ensure a successful steel fuel tank project.
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Cutting and shaping
Building a steel fuel tank requires careful planning and execution, especially when it comes to cutting and shaping the metal. Here is a detailed guide to walk you through the process:
Planning and Preparation:
Before you start cutting, it is crucial to have a clear plan and pattern for your steel fuel tank. Determine the desired shape and dimensions by measuring the space where the tank will be installed. Consider the size and shape of the vehicle's available space, as well as any specific requirements for your fuel tank. Create a cardboard mockup of your fuel tank and test-fit it into the vehicle to ensure accuracy.
Choosing the Right Steel:
Selecting the appropriate type of steel is essential. Stainless steel is highly recommended due to its high resistance to corrosion and weldability. While it is more expensive than mild steel, you can avoid the additional cost of coatings required for mild steel. Ensure your steel sheets are clean and free from oil, rust, or any other impurities that could affect the integrity of your welds.
Cutting the Steel Sheets:
When it comes to cutting the steel sheets, use a skill saw with a 40-50 teeth carbide blade. Clamp down your steel sheet securely before beginning the cutting process. Cut the largest blank to size first, as this will form the main body of your tank. You can then cut the end caps and any other required pieces to size, ensuring they fit together seamlessly.
Shaping the Steel Pieces:
Once your steel pieces are cut to size, it's time to shape them. Use Round-Over dies on a beading machine to curl the edges of the steel pieces where the joints will be welded. This step ensures uniform corners and reduces distortion from welding. For bending the steel pieces, utilize a shop-made radius bender or a commercial bending brake to create uniform bends with a consistent radius. Ensure that the final bends result in a tight fit-up, which is crucial for strong welds.
Welding and Assembly:
After shaping, you can begin the welding process. Tack-weld the pieces together, working lightly with a hammer and dolly to perfect the alignment. Then, make final welds along the seams, ensuring a strong and leak-free joint. Remember to weld any baffles or sumps into place, as these can help with fuel sloshing and provide a drain option, respectively.
Building a steel fuel tank requires precision and attention to detail, especially during the cutting and shaping phase. By following these steps and taking your time, you can create a safe and functional steel fuel tank tailored to your needs.
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Welding
When welding a steel fuel tank, it is recommended to use stainless steel as it is highly resistant to corrosion and not excessively difficult to weld. While it is more expensive than mild steel, the cost may be offset by the need to purchase expensive coatings for mild steel. Additionally, mild steel is corrosive, requiring additional steps in the construction process.
The welding process itself can vary depending on the equipment and techniques used. Some common welding techniques for steel fuel tanks include MIG welding and TIG welding. MIG welding is a popular choice due to its ease of use, but it may result in pin holes. TIG welding, on the other hand, is more tedious but can produce better results in terms of leak prevention.
It is also important to consider the shape and construction of the fuel tank. While a steel fuel tank can be made in any desired shape, it is generally better to form the four largest parts from one piece of metal by bending three corners. This reduces the amount of welding required and results in a stronger and more aesthetically pleasing tank.
After welding, it is crucial to test the tank for leaks. This can be done by pressurizing the tank with an air compressor and using soapy water along the seams to check for any leaks. A pressure of 2-3 psi is generally sufficient for this test.
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Testing for leaks
Air Pressure Test
The air pressure test is one of the most common methods for detecting leaks in a steel fuel tank. This test involves pressuring the tank with air and monitoring for any pressure drops, which indicate potential leaks. To perform this test, you should:
- Seal the tank securely.
- Use an air compressor to pressurize the tank with air.
- Monitor the pressure readings carefully. Any drop in pressure suggests a potential leak.
- For greater accuracy, you can use specialized equipment, such as aviation welding technicians, to pinpoint the exact location of the leak.
Liquid Fill Leak Test
The liquid fill leak test is often conducted after the air pressure test to further ensure the tank's integrity. This test involves filling the tank with a non-flammable liquid and checking for any signs of fluid escaping. Here's how to perform this test:
- Carefully fill the tank with a non-flammable fluid.
- Monitor the tank for any leaks or signs of fluid escaping.
- This test is especially useful for identifying smaller leaks that the air pressure test might not detect.
Bubble Test
The bubble test is a basic and cost-effective method for leak detection. It involves submerging the tank in water and looking for bubbles, which indicate the presence of leaks. While this method is simple, it is only suitable for detecting larger leaks.
Liquid Penetrant Inspection
This is a meticulous inspection process that requires specialized skills. It involves applying a special dye to the surface of the fuel tank and then examining it under ultraviolet light to identify any cracks or defects. This test is crucial for ensuring the structural integrity of the tank and can detect even the smallest imperfections that could lead to potential leaks.
Other Considerations
- When performing air pressure tests, be cautious not to exceed a few PSI (pounds per square inch) as it can deform the tank.
- You can use soapy water or a bubble soap solution along the seams of the tank to help identify leaks more easily.
- Some specifications, such as UL specs, require specific pressure tests and hold times or even destructive tests prior to production building. Ensure you are aware of the requirements your tank needs to meet.
- Always prioritize safety during the leak testing process. An incident involving a British aeroplane company resulted in an explosion due to the pressure not being relieved from a fuel tank.
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Frequently asked questions
Stainless steel is a great option as it is highly resistant to corrosion and not too difficult to weld. However, it is more expensive than mild steel. Aluminium is another option, as it is lightweight, easy to form, and won't rust, but it is incredibly difficult to weld.
Steel fuel tanks can be made in any shape, but most gas tanks are rectangular, which makes them easier to fabricate and fit into most spaces.
First, measure the space where the tank will go and determine the desired shape and dimensions. Then, cut the metal to size and weld the pieces together. You will also need to decide whether to include features such as baffles to deal with "tank slosh". Finally, coat the inside and outside of the tank to prevent corrosion.
You can test for leaks by pressurising the tank with an air compressor and using soapy water along the seams to look for bubbles.
You can use an unvented/sealed cap and run a vent with a roll-over valve to keep fuel in while still venting.
