Sylvie Willis
Aluminium is a popular choice for fuel tanks due to its light weight, stability, and resistance to corrosion. However, it is notoriously difficult to weld, and many workshops do not offer aluminium welding services. Nevertheless, it is possible to create an aluminium fuel tank at home, and there are several methods to do so. This article will outline the steps and considerations for building a custom aluminium fuel tank, including design, materials, and construction.
Characteristics and Values Table for Creating an Aluminum Fuel Tank
| Characteristics | Values |
|---|---|
| Materials | .040" or .050" weldable aluminum, 2024 T3-grade aluminum alloy sheet, 1100, 3003, 5052, or 6061 series of aluminum sheet |
| Welding | Difficult; may require expert instruction and practice or a local welder; alternative methods include using aircraft rivets or heliarc welding |
| Design | Consider tank slosh and fuel sump to prevent fuel starvation; construct a prototype or cardboard model to test the design and fit |
| Coating | Necessary for both the inside and outside of the tank to prevent corrosion; stainless steel is an alternative material that is highly resistant to corrosion |
| Weight | Aluminum is lighter than steel of equal strength |
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What You'll Learn
Aluminium is a good choice due to its resistance to corrosion
Aluminium is a good choice of material for a fuel tank due to its resistance to corrosion. Aluminium is a stable, clean, and easy-to-work-with metal that always yields predictable results. It is also about 33% lighter than steel of equal strength, making it a superior choice for fuel tank construction.
Aluminium's resistance to corrosion is due to its high reactivity with oxygen, which forms a protective layer of aluminium oxide on its surface. This layer acts as a shield, preventing further oxidation of the aluminium underneath. This natural oxide layer is only 5-10 nm thin but is effective in preventing metal rust when exposed to water. The oxide film's stability determines its resistance to corrosion, which depends on the pH value of the environment. Typically, oxide films are stable in the pH range of about 4 to 8.
The corrosion resistance of aluminium can be further enhanced through processes such as anodizing and alodining. Anodizing involves submerging the metal in an electrolytic bath, thickening the natural oxide layer and improving its protective capabilities. Alodining, on the other hand, creates a thin protective film on the metal through a conversion coating process.
The purity of aluminium also plays a role in its corrosion resistance. Pure aluminium, such as the 1xx.x series alloy, has very low measured corrosion rates due to the absence of metallic elements in its microstructure. However, the addition of alloying elements like copper or zinc can decrease corrosion resistance while increasing strength and ductility.
While aluminium is an excellent choice for its corrosion resistance, it is important to note that welding aluminium can be challenging. Most builders cannot weld aluminium and often require expert instruction and practice to master this skill. However, this should not deter one from choosing aluminium for a fuel tank, as there are alternative methods, such as riveting, to construct the tank without welding.
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Welding aluminium is difficult and requires expertise
Aluminium welding requires different techniques and processes than welding steel. The welder must be careful not to burn holes in the metal, as the oxide layer melts at a much higher temperature than the aluminium underneath. The metal also becomes porous and weak in its molten state as it absorbs hydrogen, which separates and leaves bubbles when it returns to a solid form.
Aluminium's lower melting point is reached very suddenly due to its high thermal conductivity. This means that it is a challenge to weld successfully, and it can be tricky to work with. It is essential to choose the right welding process, such as TIG or MIG welding, to ensure a successful weld.
Despite the challenges of welding aluminium, it is a skill that can be developed with the right knowledge and practice. Aluminium is a clean, stable, and easy-to-work-with material that always yields predictable results. It is also lightweight and highly resistant to corrosion, making it an excellent choice for fuel tanks.
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Aluminium is lighter than steel
Aluminium is about 33% lighter than steel of equal strength. This makes it a superior choice for fuel tank construction. For two pieces of equal volume, steel can weigh up to three times as much as aluminium.
Aluminium's lower weight means it has a better strength-to-weight ratio than steel. This means that a larger aluminium part can offer more strength at a lower weight than a steel alternative. This is particularly important in the automotive and aerospace industries, where weight reduction is a key factor. For example, in the aerospace industry, a chunk of aluminium with local reinforcements can provide better protection than plates of stainless steel at a lower weight.
Aluminium's lower weight also means it is easier to work with and shape than steel. It can be easily bent into various shapes, making it a good choice when a unique shape is required. This flexibility also means that aluminium can be used to create larger fuel tanks without adding too much weight.
While aluminium is a good choice for fuel tanks due to its light weight, there are some downsides to this material. Aluminium is difficult to weld, and most builders have not tried to weld it. It does not change colour as its temperature increases, and its lower melting point is reached very suddenly due to its high thermal conductivity. This can lead to the metal suddenly puddling and collapsing, which can be a problem for welders who are not experienced with aluminium. However, it is still possible to construct an aluminium fuel tank without welding, using aircraft rivets to assemble the tank instead.
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Create a prototype to avoid costly mistakes
Creating a prototype is an essential step in building an aluminium fuel tank, as it allows you to test your design before committing to the final product. This step will help you avoid costly mistakes and ensure that your fuel tank fits perfectly in the designated space. Here are some detailed instructions to guide you through the process of creating a prototype:
Step 1: Measurements and Design
Begin by taking precise measurements of the space where you plan to install your aluminium fuel tank. Consider the required space for fuel pick-ups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. Draw your design on paper, incorporating all the necessary measurements. This step may be time-consuming, but it is crucial for ensuring an accurate fit.
Step 2: Create a Cardboard Prototype
Using cardboard, create a prototype of your fuel tank. Cardboard is an excellent material for prototyping because it is inexpensive and easy to work with. Cut out the individual pieces of your prototype based on your design measurements. Tape the pieces together to form a three-dimensional model of your fuel tank. This prototype will help you visualise how the final product will look and fit in the intended space.
Step 3: Test Fitting
Now, it's time to test the fit of your cardboard prototype in the designated space. Place the prototype in the area where you plan to install the fuel tank. Ensure that it fits correctly and doesn't interfere with any surrounding components. Check if there is sufficient clearance from heat sources, such as the exhaust, and consider the need for heat shielding.
Step 4: Refine and Finalise the Design
If your prototype doesn't fit perfectly, make the necessary adjustments to your design. Modify the cardboard prototype accordingly and repeat the test-fitting process until you achieve the desired fit. This iterative process will help you refine and finalise your design before moving on to the next steps.
Step 5: Choose Materials and Welding Techniques
Select the appropriate aluminium material for your fuel tank, such as weldable aluminium alloys like the 1100, 3003, 5052, or 6061 series. Consider the advantages and disadvantages of welding versus riveting. If you choose welding, you may need to consult a local welder for assistance, as aluminium can be challenging to weld. Alternatively, you can assemble your tank with aircraft rivets and seal the seams with a fuel-proof compound.
Step 6: Address "Tank Slosh"
Consider how you will manage "tank slosh," which is the movement of fuel inside the tank during acceleration or turning. One solution is to use fuel-resistant foam to slow down the sloshing motion. Another approach is to divide the tank into smaller sections with trap doors or small holes, preventing fuel from starving the fuel pump during rapid movements.
By following these steps and creating a prototype, you can avoid costly mistakes, refine your design, and ensure a successful aluminium fuel tank project.
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Use a fuel-proof compound to seal riveted seams
If you decide to assemble your aluminium fuel tank with aircraft rivets, you must seal the riveted seams with a fuel-proof compound. This is because, even if you achieve good tight seams, you will still need to ensure they are leak-proof.
There are a number of fuel-proof compounds available on the market, such as POR-15 Fuel Tank Sealer, Alcohol Resistant Gas Tank Sealer, and U.S. Standard Fuel Tank Sealer. These compounds are designed to be poured into the fuel tank and the tank rotated so that the material coats the inside walls of the tank. Some thicker materials may require a brush to spread the material. It is important to note that the shelf life of most fuel tank sealants is approximately six months at room temperature, so you should only order the sealant when you are ready to use it.
Before applying the sealant, it is essential that the metal tank surfaces are thoroughly cleaned with a suitable product, such as methyl ethyl ketone (MEK) or Naptha. You should also be sure not to touch the cleaned surfaces with your bare hands, as body oils will ruin the seal. After the rivets have been upset, run a 1/8" bead or fillet of sealant along every rib, seam, corner, joint and rivet. You should also add plenty of filler rod to the seams.
It is worth noting that, while aluminium is a popular choice for fuel tanks due to its light weight and resistance to corrosion, it is difficult to weld. As such, you may need to take your completed fuel cell to a local welder to have it welded for you.
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Frequently asked questions
You will need .040" or .050" weldable aluminum. If you don't want to weld, you can use 2024 T3-grade aluminum alloy sheet and assemble the tank with aircraft rivets. Other materials include a homemade flange bending gadget, a bandsaw, and a fuel-proof compound to seal the rivets.
First, create a prototype using cardboard to ensure your design fits in the area where you plan to place the fuel tank. Then, cut out the pieces of your fuel tank using a bandsaw or jigsaw. Next, bend the pieces to shape using a homemade flanging tool. Finally, assemble the pieces by clamping or welding them together.
Aluminum is about 33% lighter than steel of equal strength, making it a good choice for fuel tank construction. It is also easy to work with, clean, stable, and resistant to corrosion due to the oxidation layer that develops on exposed aluminum.
