Regan Brown
PVC pipes are a popular material for DIY projects due to their versatility and ease of use. Some enthusiasts have explored the possibility of using PVC pipes for fuel tanks, particularly for motorcycles and aircraft. While PVC offers a cheap and lightweight alternative to metal tanks, there are concerns about its compatibility with gasoline and potential safety hazards. To address this, some suggest testing PVC samples in fuel for a week to observe any reactions. Others propose lining the inside of the tank with a coating or using alternative materials like copper tubing. Despite the challenges, PVC fuel tanks present an innovative solution for those seeking a cost-effective and unique approach to fuel storage.
Characteristics and Values Table for Making a Fuel Tank from PVC
| Characteristics | Values |
|---|---|
| Materials | PVC pipe, glue, copper tubing |
| Testing | Soak a sample in fuel for a week to check compatibility |
| Coating | Line the inside of the tank with a coating to prevent fuel incompatibility |
| Venting | Create a vented cap |
| Sealing | Leak-proof seal |
| Weight | Lighter than metal tanks |
| Safety | Ensure all materials are approved for use with fuel |
| Cost | PVC is a cheap option |
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What You'll Learn
Testing PVC and gasoline compatibility
Firstly, it is crucial to understand the potential challenges associated with using PVC for fuel tanks. PVC is a plastic that undergoes a continuous chemical process, leading to ageing and brittleness over time. Additionally, the success of a PVC fuel tank depends on the compatibility of both the PVC material and the glue used to weld its joints.
To test the compatibility of PVC with gasoline, one recommended method is to obtain a sample of the specific PVC material you intend to use and soak it in gasoline for an extended period. The duration of soaking can vary, with some sources suggesting a day or two, while others recommend a week or longer. During and after this soaking period, carefully examine the PVC sample for any signs of swelling, softening, or other physical changes. If the PVC remains unaffected, it suggests that it may be compatible with gasoline.
It is worth noting that temperature can influence the compatibility of PVC and gasoline. Chemical compatibility charts, such as the one referenced by a user on BobIsTheOilGuy, indicate that rigid PVC is considered compatible with gasoline at a temperature of 20°C (68°F), but the compatibility rating changes to "Not Recommended" at a higher temperature of 50°C (122°F). Therefore, it is essential to consider the operating temperature of your fuel tank when interpreting the test results.
Another aspect to consider is the type of PVC. Flexible vinyl, for example, contains low molecular weight materials that soften the PVC. Gasoline can leach out these materials, leading to hardening and potential issues in the carburetor. Rigid PVC is generally considered more compatible with gasoline than its flexible counterpart.
While these tests provide valuable insights, it is important to recognise their limitations. Some forum users have expressed that the piece of tubing in a jar test may not always be reliable, and longer testing durations are recommended to truly understand the compatibility. Additionally, these tests focus primarily on the PVC material itself and do not account for the potential effects on glue or vibration-induced leaks at the joints. Therefore, it is essential to complement these compatibility tests with considerations for proper gluing techniques and joint reinforcement to ensure the overall integrity of the fuel tank.
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Using coatings to line the tank
If you're making a fuel tank from PVC, it's important to consider the compatibility of the material with gasoline. PVC can break down and become sticky when exposed to certain fuels, so it's crucial to test the compatibility before use. One way to address this issue is by lining the inside of the tank with a suitable coating.
There are several types of coatings that can be used to line a fuel tank, each with its own advantages and suitability for specific applications. Epoxy coatings, for example, are known for their strong adhesion to various materials, including metal and fiberglass. They offer excellent resistance to corrosion and chemicals, making them ideal for tanks storing aggressive fuels or operating in harsh environments. Epoxy coatings are composed of an epoxy resin and a hardener, which form a robust and resistant bond when mixed.
Polyurethane coatings are another popular choice due to their outstanding flexibility and durability. They offer excellent resistance to abrasion and impact, making them suitable for tanks in mobile applications or those exposed to mechanical stress. The flexibility of polyurethane allows the coating to expand and contract without compromising its integrity, which is crucial in varying temperature conditions. Additionally, polyurethane coatings provide UV resistance, making them suitable for external tanks exposed to sunlight.
Phenolic coatings are commonly used in high-temperature environments due to their heat resistance. They are compatible with various chemicals, including certain fuels and solvents, and provide a good barrier to prevent the permeation of fuels and gases. Fluoropolymer coatings, on the other hand, are specialised coatings offering exceptional chemical resistance. They are non-stick, aid in the easy release of substances from tank walls, and are resistant to UV rays and extreme weather conditions.
The selection of the appropriate coating depends on the intended usage of the tank and the environmental factors it will be exposed to. Application methods such as spraying, brushing, or rolling are chosen based on the tank's size and shape. Multiple layers of coating may be applied, with proper curing time allowed between each layer. Curing methods can include air-drying, heat, or UV light, depending on the coating type.
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Tank venting and sealing
Venting:
Venting systems are essential in fuel tanks to mitigate safety risks. As fuel is consumed, a vacuum is created, which can lead to tank deformation or collapse if not properly vented. Additionally, changes in temperature can cause fuel expansion, resulting in pressure buildup and potential tank rupture. Proper venting releases pressure, preventing explosions or ruptures. It also maintains a vacuum, stopping fuel from being forced out due to pressure changes.
When designing your PVC fuel tank, consider implementing a vented cap and equalizer tube to ensure proper ventilation. The vent should be mounted vertically to function correctly and prevent accidental shut-off. This setup will allow air to flow in and out, maintaining safe pressure levels.
Sealing:
Sealing your PVC fuel tank is critical to prevent leaks and spills. Before sealing, test the compatibility of PVC with your intended fuel by soaking a sample in the fuel for a week. If they are incompatible, consider lining the tank's interior with a suitable coating.
Ensure all connections and fittings are securely sealed to avoid fuel leakage. Pay close attention to the vent and filler tube areas, as these are potential leak points. Proper sealing will maintain the integrity of your fuel tank and prevent hazardous spills or leaks.
Remember, the specific design of your venting and sealing system may vary depending on your tank's size, type, and intended use. Always prioritize safety and follow best practices to create a functional and secure PVC fuel tank.
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Mounting the tank
When it comes to mounting your PVC fuel tank, there are several important considerations and methods to keep in mind. Firstly, safety is a primary concern, and it's crucial to ensure that your PVC tank complies with the relevant standards and regulations. In the case of Schd. 40 PVC, for example, it is noted that this type of PVC is not approved for use with fuel. Always verify that your chosen materials are suitable for their intended purpose.
Another key aspect of mounting a PVC fuel tank is the method of attachment. One common approach is to strap the tank in place, as suggested by some aircraft enthusiasts. This method allows for easy access and the ability to carry extra fuel. However, it is important to obtain the necessary permits and approvals, especially when dealing with aircraft fuel systems, as regulations may apply.
The size and shape of your PVC fuel tank will also influence the mounting process. For instance, shorter tubes may be more manageable and can be strapped onto struts or other structural elements. Consider the available space and any potential obstructions when planning the location of your fuel tank. Additionally, the weight of the tank and the fuel it carries should be factored into the mounting design to ensure that the structure can adequately support the load.
To ensure a secure mount, the use of appropriate fasteners and hardware is essential. This may include straps, brackets, or other specialized mounting equipment. Consider the vibrations and stresses that the tank may be subjected to during use and select mounting components that can withstand these conditions. It is also important to assess the compatibility of the mounting materials with the fuel type to prevent any unwanted chemical reactions or degradation.
Lastly, the mounting process should allow for easy access to the fuel tank for refuelling, maintenance, and inspections. Consider the location of the tank in relation to the fuel filler cap and any necessary ventilation. By planning the mounting location carefully, you can ensure that routine tasks associated with the fuel system are convenient and straightforward. Remember to follow all safety protocols and guidelines specific to your application when mounting and using your PVC fuel tank.
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Using PVC tubes to haul fuel
If you are satisfied with the compatibility, you can begin constructing your PVC fuel tank. Consider the size of the tank you require and opt for a tubular shape if you're looking for something simple. A 2" diameter tank should be sufficient for most applications. One of the challenges of using PVC for a fuel tank is creating a vented cap and a leak-proof pickup/equalizer tube. You will need to get creative to ensure your fuel tank is safe and effective.
When it comes to filling up your PVC fuel tank, leave the spout by the inspection plate. Use a small hand pump to fill it up, and don't worry too much about the small amount of fuel lost when putting the cap on the bladder. Simply replace the inspection plate, and you're good to go. To transfer the fuel from the bladder to your vehicle's tank, remove the inspection plate and use a hand siphon to pump the fuel.
It is important to note that not all PVC types are approved for use with fuel. Schd. 40, for example, is not suitable, and you must ensure that any epoxy you use is approved for creating a sealed joint with PVC. Always check the relevant regulations and guidelines before constructing and using a PVC fuel tank.
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Frequently asked questions
It is not recommended to use PVC to make a fuel tank as it is not approved for use with fuel.
K & S copper-tube plumbing is a good alternative.
Rotopax makes narrow fuel cans that are only 3 inches wide. Fuel bags from Bushwheel Bill are also a great option.
Weight, sealing, venting, and mounting are all important considerations when using PVC for a fuel tank. It is also important to test the compatibility of the PVC with the fuel by soaking a sample in the fuel for a week.
PVC pipes can be used to create a variety of items such as gun stocks, desk lamps, and fuel tanks. The tubular shape of some PVC tanks can be aesthetically pleasing.
