Sylvie Willis
Metal fuel tanks are usually lighter than fibreglass tanks of a similar capacity. Common materials used to make metal fuel tanks include aluminium, mild steel, and stainless steel. Before beginning construction, it is recommended to create a cardboard model of the tank to ensure it fits in the allocated space. When cutting sheet metal, it is important to ensure that everything is clamped down securely. Metal fuel tanks can be welded or assembled with aircraft rivets and sealed with a fuel-proof compound.
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What You'll Learn
Choosing the right material
Mild steel, for instance, is a viable option, but it is important to remember that it is corrosive. This means that you will need to take additional construction steps, such as coating the tank to prevent corrosion. However, as some have found, coatings may not hold up well over time and can be tedious to apply. Therefore, the extra cost of stainless steel might be justified.
Stainless steel is highly resistant to corrosion and is a great material for making a fuel tank. While it is more expensive than mild steel, you can avoid the additional cost of coatings. Stainless steel is also not terribly difficult to weld, making it a good choice if you lack the ability to weld aluminium.
Aluminium is another popular choice for fuel tanks due to its extreme resistance to corrosion. The oxidation layer that develops on exposed aluminium provides excellent protection. Additionally, aluminium is a clean, stable, and easy-to-work-with material that yields predictable results. However, welding aluminium can be challenging and typically requires specialised equipment and expertise.
Ultimately, the right material for your metal fuel tank depends on various factors, including your budget, the availability of specialised equipment and expertise, and the desired level of corrosion resistance and ease of welding. Remember to consider the specific requirements of your project and select the material that best suits your needs.
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Cutting and shaping
Making a metal fuel tank requires careful planning and execution, especially when it comes to cutting and shaping the metal sheets. Here is a step-by-step guide to help you through the process:
Planning and Preparation:
Before you start cutting, it's crucial to have a clear idea of the size and shape of your fuel tank. Consider the space where the tank will be mounted and determine the dimensions accordingly. It's recommended to keep the design as simple as possible, avoiding odd shapes that may complicate the fabrication and installation process. Create a cardboard model of your tank to ensure the dimensions are accurate and it fits well in the intended space.
Choosing the Right Metal:
Select the type of metal you want to use for your fuel tank. Common choices include stainless steel, mild steel, and aluminum. Each metal has its own advantages and disadvantages in terms of corrosion resistance, weldability, and cost. For example, stainless steel is highly resistant to corrosion and relatively easy to weld, while mild steel is more susceptible to corrosion and may require additional steps during construction. Aluminum is another popular choice due to its corrosion resistance and ease of working, but it can be challenging to weld without the proper equipment and expertise.
Cutting the Metal Sheets:
Once you've chosen your metal, it's time to cut the sheets to size. Clamp down the metal sheets securely to ensure stability during cutting. You can use a skill saw with a 40-50 teeth carbide blade to cut through the metal. Make sure to wear appropriate safety gear, including eye and ear protection, during the cutting process. Cut the metal sheets according to your cardboard template, marking the dimensions on the metal before cutting.
Shaping the Metal Sheets:
After cutting, you'll need to shape the metal sheets to form the walls and bottom of the fuel tank. This can be done using a bending or forming technique. One method is to use a brake to form the edges of the metal sheets, creating the desired shape for the tank's sides and bottom. Another approach is to use a homemade flanging tool to bend a flange into one of the skins, allowing you to assemble the skins together by clamping their edges. Ensure that your bends and flanges are precise and consistent to achieve a well-fitted shape for your fuel tank.
Finalizing the Shape:
Before moving on to welding and assembly, double-check that all your metal pieces fit together securely. Make any necessary adjustments to ensure a tight fit. Remember that fuel tanks should be constructed with as few separate pieces of metal as possible to reduce potential leak points. Consider adding baffles to your design, which can strengthen the tank and minimize fuel sloshing during maneuvers.
By following these steps, you'll be able to cut and shape the metal sheets accurately, setting a solid foundation for the rest of your metal fuel tank construction process. Always prioritize safety and attention to detail throughout the project.
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Sealing and coating
One commonly used sealant is POR-15 Fuel Tank Sealer. However, some users have reported issues with this product, stating that it peeled off and caused clogging issues. As an alternative, Northern Fuel Tank Sealer has been mentioned as a more effective option. It is important to clean and prepare the metal surface before applying any sealant, removing oil and surface rust.
Aircraft sealant can also be used to seal welds and pinhole leaks. This sealant is effective for small leaks, but it is crucial not to exceed the recommended pressure levels to avoid explosions.
For coating the tank, a fuel tank-specific gel or epoxy coating designed to make the tank rustproof can be used. This process typically involves two steps. First, the interior of the steel tank is etched with an acid component provided by the manufacturer. Then, the coating is poured into the tank, rotated to ensure all sides are coated thoroughly, and the excess is poured off. The tank is then left to dry outside for a couple of days.
When constructing a metal fuel tank, it is essential to consider the number of separate pieces used. Simplifying the design by using fewer parts can help reduce potential issues. Additionally, the use of baffles can strengthen the tank and minimize fuel sloshing.
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Welding
First, it is important to select the appropriate metal for your fuel tank. Stainless steel is a popular choice due to its high resistance to corrosion. It is relatively easy to weld compared to other materials like aluminum, which can be challenging to work with and requires specialized equipment. Aluminum, however, is clean, stable, and yields predictable results. Mild steel is another option, but it is corrosive and requires additional construction steps.
Before welding, ensure that the metal is properly prepared. Clean the steel of any oil and surface rust using chemical metal prep to ensure a clean interior surface. This is crucial to prevent issues with the sealer peeling off later.
When welding the tank, it is recommended to use tack welding in many places to keep things square and prevent movement. Clamp your tank in as many places as possible before starting. Move around and weld different areas of the tank, rather than focusing on a single section. Almost the entire fuel tank should be tacked together before any final welding is done.
Consider using a combination of welding techniques for optimal results. TIG welding, for example, can be tedious but may be better suited for the job than MIG welding, which can leave pin holes.
To ensure a leak-free weld, you can use aircraft sealant to seal the welds. Additionally, you can use flux and soft solder to seal the filler and fix leaks. Always test your tank for leaks after welding. You can fill the tank with water and apply a few PSI of air pressure to locate any leaks.
Finally, consider using baffles inside the tank. Baffles can be welded in to minimize fuel sloshing and strengthen the tank by increasing rigidity. They can also help reduce the number of welded seams and simplify the assembly process.
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Testing for leaks
Leak testing is an essential process that ensures the integrity and safety of metal fuel tanks. Metal fuel tanks are typically made from steel or aluminium and are known for their strength and ability to withstand high pressure. Given the critical nature of fuel tanks, leak testing is a fundamental step in manufacturing, maintenance, and quality control processes.
The testing pressure of fuel tanks varies depending on their size and material composition. For example, motorcycle fuel tanks are typically tested at pressures ranging from 50-75 mbar, while larger tanks used in heavy-duty vehicles may be tested at pressures exceeding 700 mbar. Metal fuel tanks generally have lower leak rates than plastic tanks, with rates typically ranging from 0.1 to 0.5 Pa/s.
One common method for testing leaks in metal fuel tanks is pressure testing. This involves purging the tank of any gasoline fumes and then using an air compressor to fill the tank with pressurised air. Soapy water is then applied to the tank, and any leaks will cause the soap solution to bubble. This method can be used to test for leaks in the welds, seams, or other areas of the tank. It is important to note that when pressure testing metal fuel tanks, it is recommended to not exceed a pressure of 2-3 psi to avoid damaging the tank.
Another method for testing leaks is to use specialised leak detection equipment, such as the ATEQ F600HP, which can test leak rates at high pressures. This type of equipment is particularly useful for testing fuel system assemblies, including fuel tanks, valves, fuel lines, connectors, and fuel injectors, to ensure their integrity and safety.
It is important to remember that the consequences of undetected leaks in fuel tanks can be severe, ranging from environmental contamination and regulatory fines to fires, explosions, and other catastrophic accidents. Therefore, proper leak testing is crucial to ensure the safety and integrity of metal fuel tanks.
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Frequently asked questions
You can use sheet metal, such as steel or aluminium. Steel is typically cheaper but is corrosive, so you will need to add a few steps to your construction. Aluminium is resistant to corrosion due to its oxidation layer, but it is difficult to weld unless you have the right equipment. Stainless steel is also an option and is highly resistant to corrosion and not terribly difficult to weld.
First, create a cardboard model of your tank and replicate all the pieces of the tank over onto your metal. You can cut the metal with a skill saw and a 40-50 teeth carbide blade. Be sure to clamp everything down before cutting. Then, weld your metal fuel tank together. You can also use aircraft rivets so that no welding is necessary. Finally, coat the inside and outside of the tank. You can use a fuel tank-specific gel/epoxy coating to make it rustproof.
Before welding, clamp your tank in as many places as possible. Tack weld in many places to keep things square and to prevent movement. You can also use flux and soft solder to seal the filler and fix leaks. To test for leaks, fill the tank with water and add a few psi of air to locate any leaks.
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