Rajan Wilcox
Building a fiberglass diesel fuel tank is not a beginner project and requires careful consideration. It is a time-consuming and challenging process that involves several steps, including selecting the appropriate resin, addressing the petcock and fuel cap mounts, and ensuring proper sealing to prevent fuel damage to the fiberglass. Some people choose to customize their tanks, while others opt for prebuilt panels. It is important to learn from the experiences of others, such as the recommendation to use aluminum tanks with proper ventilation for longevity. Additionally, the use of fuel bladders and the impact of weight on the boat should be considered. Overall, constructing a fiberglass diesel fuel tank demands expertise and a thorough understanding of the process.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Difficulty | Not a beginner project |
| Materials | Fiberglass, resin, sealer, foam, saran wrap, paste wax, glass, body putty, aluminum, polyethylene, plastic, rubber |
| Tools | Sandpaper, fiberglass gel |
| Cost | $3,500 for a pair of 80x17x15 saddle tanks |
| Time | Time-consuming |
| Safety | Potentially dangerous |
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What You'll Learn
Choosing the right resin
When it comes to choosing the right resin for your fiberglass diesel fuel tank, there are several factors and options to consider. Firstly, it is important to select a resin that is compatible with diesel fuel and the fiberglass material. While the specific resin formulation may vary depending on the fuel type, diesel fuel tanks are generally simpler in terms of requirements.
One recommended option is to use an ISO PE (Isopthalic) or VE (vinylester) resin. These resins are often rated well for diesel fuel tanks. However, it is important to note that different resin formulations have unique properties, so you should consider the specific needs of your project. For instance, you might want to consider waxing or using a finishing resin on the last coat of resin to prevent the diesel fuel from interacting with an uncured surface.
Another important consideration is the safety aspect. Some sources recommend using a gasoline-safe resin, such as polyester or vinyl-ester resin, to repair fuel tanks. These resins can provide a strong and durable solution. However, it is crucial to ensure that the resin is compatible with diesel fuel and will not break down over time due to continuous exposure to the fuel.
Additionally, you may want to explore epoxy resins, which are known for their strength and durability. The West System 105 resin, combined with the 209 extra slow hardener, has been used successfully for fuel tanks. Epoxy resins, such as the EZ POXY 87 hardener, are also recommended for their compatibility with gasoline, although they may come at a higher cost and be intended for larger-scale applications.
Ultimately, the choice of resin depends on various factors, including compatibility, safety, cost, and availability. It is always advisable to consult with professionals or seek advice from reputable sources to ensure that your fiberglass diesel fuel tank meets the necessary safety standards and performs as expected.
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Sealing the tank
Before sealing, it is essential to prepare the tank surface. Sanding the shell of the tank is necessary to smooth out any imperfections and create a uniform surface. This can be done using a combination of techniques, such as sanding, applying a fiberglass gel, and using body putty for minor imperfections. Ensuring that the tank surface is thoroughly cleaned and free of any contaminants is also crucial before sealing.
The type of sealer to be used is an important consideration. A compatible sealer that effectively adheres to the fiberglass material is essential. One recommended option is the Caswell sealer, which has been mentioned as a good choice for fiberglass tanks. Another highly regarded product is the KBS Coatings Gold Standard, which has proven effective in sealing fiberglass tanks used with ethanol-tainted fuel. It is important to research and select a suitable sealer that meets your specific requirements.
When applying the sealer, ensure that you follow the manufacturer's instructions carefully. Each sealer may have specific application guidelines, so it is important to read and understand the process beforehand. Proper ventilation during the sealing process is crucial, especially when dealing with volatile compounds. Personal protective equipment, such as gloves and respirators, should be worn to safeguard against any chemical exposure.
After applying the sealer, allow adequate curing time for the sealant to fully harden and cure. This timeframe can vary depending on the product used and environmental conditions. Refer to the manufacturer's guidelines for the recommended curing time and any specific instructions for optimal curing conditions. Once the sealant has cured, it is important to test the tank for any leaks. This can be done using various methods, such as pressure testing or filling the tank and monitoring for any leaks over a period of time.
Finally, it is worth noting that sealing a fiberglass diesel fuel tank is a complex process that requires careful planning and execution. While creating a custom tank can be rewarding, it is not a beginner's project. Consider seeking advice and guidance from experienced individuals or professionals before attempting to build and seal a fiberglass diesel fuel tank.
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Using a fuel bladder
Fuel bladders can be quickly deployed and filled, making them perfect for emergency situations and temporary storage needs. They are suitable for both residential and industrial applications. For smaller tanks, many customers prefer transporting these units to different locations for temporary fuel storage. Larger tanks are ideal for extensive fuel storage needs. Common applications include providing a reliable fuel supply on construction sites, storing large quantities of fuel for industrial operations, and ensuring fuel availability in remote locations.
When using a fuel bladder, it is important to consider the weight and placement of the bladder. It is recommended to build a cradle for the bladder to ensure stability. Additionally, when filling up the bladder, it is inevitable that there will be spills and leaks, so it is important to be prepared for diesel getting in places where it shouldn't be.
Fuel bladders are available in a wide range of sizes, from 25 to 210,000 gallons, and can be customized to fit specific storage needs, whether it's small, portable options or large, stationary tanks for long-term use.
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Using a plastic drum
Making a fiberglass diesel fuel tank using a plastic drum is a challenging project that requires careful planning and execution. Here is a step-by-step guide to help you through the process:
Selecting the Right Plastic Drum
Choose a plastic drum that is suitable for storing diesel fuel. Plastic fuel drums are commonly made from high-density polyethylene (HDPE) and are designed to withstand harsh conditions while preventing leaks and spills. Standard plastic fuel drums typically range from 5 to 55 gallons in capacity and are widely used in various industries. If you plan to store hazardous liquids, consider using a closed-head drum with a sealed top to minimize spillage. For ease of filling and cleaning, open-head drums with removable lids are a better option for non-hazardous liquids.
Preparing the Plastic Drum
Before beginning the fiberglass application, ensure that the plastic drum is clean and free from any contaminants. You may need to sand or treat the surface of the drum to create a suitable base for the fiberglass to adhere to. It is crucial to follow safety protocols and wear appropriate protective gear when working with fiberglass and resin.
Applying the Fiberglass
The fiberglass application process involves mixing the fiberglass strands or cloth with a suitable resin. There are various types of resins available, and selecting the right one is essential. Carefully read the instructions provided with your chosen resin and mix it according to the specified ratio. Apply the fiberglass mixture to the plastic drum, ensuring complete and even coverage. Use appropriate tools and techniques to smooth out the fiberglass and eliminate any imperfections.
Sealing and Finishing
Once the fiberglass has cured, you will need to seal the fuel tank to prevent leaks. Coat the inside of the tank with a suitable sealer, such as a fuel-compatible epoxy or liner. Pay close attention to the fuel neck, cap, and petcock areas to ensure they are properly sealed. Finish the exterior of the tank as desired, which may include sanding, painting, or applying a protective coating.
Testing and Installation
Before using your newly created fiberglass diesel fuel tank, thoroughly test it for leaks. This can be done by filling the tank with air or water and monitoring for any leaks or structural issues. Ensure that all fittings, connections, and hoses are secure and compatible with diesel fuel. Follow appropriate safety guidelines for fuel storage and installation, including ventilation and weight distribution considerations.
Creating a fiberglass diesel fuel tank using a plastic drum can be a rewarding project, but it requires careful planning, attention to detail, and a good understanding of the materials involved. Always prioritize safety and follow local regulations when working with flammable liquids and hazardous materials.
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Smoothing the tank
Start by sanding the tank's surface. Use a fine-grit sandpaper, such as 220-grit or higher, to smooth out any rough areas and create a uniform surface. Pay extra attention to the areas where there are noticeable imperfections or irregularities. Remember always to sand in the direction of the fibre to avoid damaging the fabric.
Once you are satisfied with the sanding, apply a fiberglass gel coat to the entire surface of the tank. This gel coat will help fill in any minor imperfections and create a smooth, even base for further smoothing. Allow the gel coat to dry completely according to the manufacturer's instructions.
After the gel coat has dried, inspect the surface for any remaining small imperfections or irregularities. Use a high-quality body putty to fill in these areas and create a smooth, flawless finish. Apply the putty with a spatula or similar tool, ensuring it is evenly distributed and flush with the surrounding surface. Again, allow the putty to dry completely.
Once the putty is dry, you can begin the final sanding process. Use a finer grit sandpaper, such as 320-grit or higher, to gently sand the entire surface of the tank. This will smooth out any final imperfections and create an ultra-smooth finish. Remember to sand with light, even strokes to avoid creating new imperfections.
Finally, you may want to consider applying a sealer or coating to the tank's surface. This step is optional but can provide added protection and a smoother finish. A sealer will help protect the fiberglass from fuel and other contaminants. Ensure you choose a sealer compatible with diesel fuel, such as Caswell or KBS Coatings, to avoid any issues.
Remember, creating a smooth finish on your fiberglass diesel fuel tank takes time and patience. Don't rush the process, as it will ensure a high-quality and durable result.
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Frequently asked questions
Building a fiberglass fuel tank is not a beginner project and requires expertise in glasswork.
The materials required include fiberglass gel, body putty, resin, sealer, and foam.
The process involves dissolving the foam, sanding the shell, using fiberglass gel for smoothing, and coating the inside of the tank with a sealer.
There are different views on the type of resin to use, with various types recommended by different people. Some recommend using vinyl ester resins, while others suggest consulting an expert like Chuck Distefano in Boston, who has built several fiberglass fuel tanks.
Yes, there are alternatives to consider, such as aluminum tanks, welded plastic tanks, or pre-built panels and bladders. Aluminum tanks, when properly built, awlgriped, and installed with ventilation, can last a long time. Pre-built panels can save time and effort in the building process.
