Rajan Wilcox
Converting a beer keg into a fuel tank is a popular project for car enthusiasts, especially those interested in hot rods. While some people have expressed safety concerns about this practice, others have successfully completed the conversion, citing the strength and durability of beer kegs. The process involves drilling and tapping the keg, as well as adding a filler spout and fuel gauge. Some people also choose to weld in a bung for a screw-in sender. The thickness and material of the keg should be considered, as well as the legal implications of using a keg stamped with the name of a brewery or manufacturer.
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What You'll Learn
Sourcing a beer keg
The first step in making a beer keg fuel tank is, of course, sourcing a beer keg. There are a few things to consider when choosing a keg, such as the size, material, and condition of the keg.
Size
The size of the keg will depend on the specific requirements of your project. The average newer keg is a 5-gallon log keg, but larger and smaller kegs are also available. A full-size keg, for example, holds about 15 gallons, while a mini keg holds around 5 liters.
Material
Beer keg design and materials have changed over the years, and the material of the keg will impact the conversion process. Older kegs, such as the 1958 vintage aluminum keg mentioned in one forum post, may have features that make the conversion easier, such as a large fill flange that allows for direct installation of the filler neck and fuel lines.
Condition
When sourcing a used keg, it is important to inspect its condition carefully. The keg will need to be cleaned and sanitized before use, and any small parts, such as the gas dip tube, may need to be soaked in a cleaning or sanitizing solution. It is also worth checking for any stamps or markings on the keg that may indicate it is the property of a brewer or manufacturer, as there may be legal implications to using a keg with these markings.
Where to Buy
Beer kegs can typically be purchased or rented from liquor stores, breweries, wineries, and even some restaurants. Northern Brewer offers a range of new and used kegging equipment, including kegs, faucets, taps, and small parts. When buying or renting a keg, it is important to plan in advance, as some places may require orders to be placed at least 10 days ahead of time.
Legal Considerations
It is important to note that converting a beer keg into a fuel tank will likely not be DOT-approved. There may also be legal implications if the keg is stamped as the property of a brewer or manufacturer. When renting a keg, there are usually requirements that must be met, such as providing proof of age and signing paperwork accepting responsibility for the keg and its contents.
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Choosing the right keg material
When choosing a beer keg to convert into a fuel tank, it is important to consider the material it is made from. Beer kegs are typically made from stainless steel or aluminium, and both materials have their advantages and disadvantages when being used as a fuel tank.
Stainless steel kegs are stronger and more durable than aluminium kegs, which can crack if dropped or hit. Stainless steel is also easier to weld than aluminium, which is an important consideration when converting a keg into a fuel tank, as welding will be necessary to attach fittings and connections. However, stainless steel kegs are often newer and may have a smaller fill flange, requiring more welding to attach the necessary fittings.
Aluminium kegs, on the other hand, are typically older and may have a larger fill flange, making it easier to install the filler neck, fuel pickup, and fuel return line without the need for welding. Additionally, aluminium is a lighter material than stainless steel, which can be beneficial for weight savings in a vehicle.
Another factor to consider is the thickness of the keg material. Some aluminium kegs may have thicker walls than stainless steel fuel cells, which can provide added strength and durability. However, it is important to ensure that the keg is thick enough to withstand the pressure and demands of a fuel tank application.
The size of the keg is also an important consideration. The average newer keg is around 5 gallons, but larger sizes, such as 15-gallon kegs, are also available. Choosing the right size will depend on the specific application and space constraints of the vehicle.
Lastly, it is important to consider the legal implications of using a beer keg as a fuel tank. Most kegs are stamped with the brewer or manufacturer's information, and using a stamped keg may have legal consequences. It is important to find a keg that does not have this stamping or to take the necessary steps to remove or cover the stamping before using it as a fuel tank.
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Drilling and tapping the tap connection
The first step is to identify the location of the tap connection on the beer keg. This is usually found on the side of the keg, often with a large aluminium fill flange. Once the tap connection is located, the drilling process can begin.
It is important to use the right tools and techniques to drill through the metal of the keg. Using a drill bit that is designed for metal drilling and ensuring that the drill is set to the correct speed and torque settings will help ensure a clean and accurate hole. It is also important to take the necessary safety precautions, such as wearing protective gear and securing the keg firmly in place to prevent it from moving during the drilling process.
After drilling the hole, the next step is to tap the connection. This involves creating threads on the inside of the hole that will allow for the secure attachment of fittings, such as a pipe plug or a weld-in bung. Tapping requires the use of a tap, which is a tool with a threaded end that matches the size and pitch of the hole. By turning the tap into the hole, the threads are cut into the metal, creating a secure connection for the fittings.
It is important to note that the process of drilling and tapping a beer keg can be complex and requires careful planning and execution. It may be necessary to consult additional resources or seek advice from experts in metalworking or fuel tank construction to ensure a safe and successful conversion.
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Installing the filler neck, fuel pickup and return line
When installing the filler neck, fuel pickup, and return line, it is important to consider the design and materials of your beer keg. For example, if you are using an older aluminium keg with a large aluminium fill flange, you may be able to install these components directly into the keg without needing to weld the fittings.
However, if your keg is made of stainless steel, welding may be required to securely attach the filler neck and other fittings. Some people prefer to weld in a threaded stainless steel nipple and then attach brass fittings to that. This can provide a strong and secure connection for your filler neck.
If you are using a plastic filler neck, consider the safety implications, especially if the tank will be located close to the driver's seat. Some people prefer to use a stainless steel filler neck and fittings for added safety and durability.
When installing the fuel pickup, you may need to weld in a flange for your gauge. Consider using a clear tube as a fuel gauge, which can be attached to the outside of the keg. This will allow you to easily monitor the fuel level.
Additionally, ensure that your beer keg fuel tank has well-sealed access ports for the fuel gauge senders and other components. Proper sealing will help prevent leaks and fumes, ensuring the safety of your vehicle.
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Ensuring safety and legal compliance
Legal Compliance:
- Ownership and Property Laws: Beer kegs typically remain the property of the brewer, as indicated by stamping or plates on the item. Using a keg that is not legally acquired can lead to legal consequences. It is important to purchase the keg from a legitimate source and keep valid receipts as proof of ownership.
- Regulatory Compliance: Using a non-DOT approved fuel tank may violate local regulations and potentially void insurance coverage. The legality of converting and using a beer keg as a fuel tank varies by region and jurisdiction. It is essential to consult and comply with the specific regulations in your area.
- Food and Beverage Container Repurposing: There may be legal implications associated with repurposing containers originally intended for food and beverage use. It is important to research and understand any restrictions or requirements specific to your location.
Safety Precautions:
- Structural Integrity: Thoroughly inspect the keg for any dents, cracks, or weaknesses that could compromise safety. Ensure the keg is in good overall condition and suitable for fuel storage.
- Cleaning and Preparation: Clean and degrease the keg thoroughly to remove any residual beer or cleaning agents. This step is crucial to prevent contamination and ensure the effectiveness of subsequent modifications.
- Ventilation and Safety Gear: Always work in a well-ventilated area when handling fuel or performing modifications. Wear appropriate safety gear, including eye protection, gloves, and respiratory protection, to safeguard yourself from hazardous substances and potential debris during the process.
- Modifications and Welding: Modifications should be carefully planned and executed to prevent leaks, explosions, or fires. Common modifications include welding new fittings for fuel lines, filler necks, and fuel gauges. Ensure that you have the necessary skills or seek assistance from qualified professionals.
- Testing and Inspection: After modifications, thoroughly test for leaks and inspect the modified keg to ensure it meets safety standards. Properly seal the keg and apply a fuel-resistant coating to prevent corrosion and leaks.
- Fuel Cap and Spark Hazards: Consider the type of fuel cap or plug used to avoid issues with softness over time or sparks in the event of an accident. A pipe cap or a brass/stainless pipe thread allen plug can help mitigate these risks.
- Fuel Cell Foam: Consider using fuel cell foam inside the keg to minimize the impact of weight shift when the tank is not completely full. This can enhance stability and reduce the risk of leakage.
Safety and legal compliance are critical aspects of converting a beer keg into a fuel tank. By diligently following the necessary precautions, consulting relevant regulations, and prioritizing safety, you can mitigate risks and ensure a successful and compliant project.
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Frequently asked questions
Beer kegs are strong and hard to dent, but they can crack. They are not DOT-approved gas tanks.
Beer kegs can be used to achieve a nostalgic look, especially for hot rods.
Design and materials of beer kegs have changed over the years, and this will impact the conversion process. For example, some kegs have a large aluminium fill flange where the fill bung is located, allowing for the installation of the filler neck, fuel pickup, and fuel return line without welding.
There are online forums and communities dedicated to car restoration and modification, such as Hotrodders.com and RatRodsRule.com, where individuals have shared their experiences and provided advice on converting beer kegs into fuel tanks.
