Mercedes Mullins
Building a custom fuel tank can be a challenging but rewarding endeavour. Whether you're working on a vintage car project or seeking to improve the fuel capacity of your vehicle, a custom fuel tank can be tailored to your specific needs. The process involves careful planning, from designing the tank's dimensions and shape to selecting the appropriate materials and construction techniques. One key consideration is the prevention of tank slosh, which occurs when fuel moves around during acceleration or cornering, potentially affecting the fuel pump's performance. To address this, methods such as dividing the tank into smaller sections or constructing a fuel sump can be employed. Additionally, the choice of materials, such as aluminium or stainless steel, plays a crucial role in the tank's weight, corrosion resistance, and ease of welding. While building a custom fuel tank can be complex, with proper measurements, prototyping, and welding techniques, it is possible to create a functional and aesthetically pleasing addition to your vehicle.
Characteristics and Values of a Custom Fuel Tank
| Characteristics | Values |
|---|---|
| Materials | Stainless steel, aluminum |
| Shape | Rectangular |
| Design | Height, width, length, filler neck, vent, roll-over valve, fuel pick-up, FI pump, radius measurement of corners, gauges, tank orientation |
| Prototype | Cardboard model |
| Welding | Tack welding, plug welding |
| Tank Slosh | Dividers, trap doors, small holes |
| Fuel Pump | Submerged fuel pump, fuel level sender, fuel sump |
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What You'll Learn
Aluminium or stainless steel are good materials to use
Aluminium and stainless steel are both excellent materials for crafting a custom fuel tank. Aluminium is lightweight, easy to form, and resistant to corrosion due to its oxidation layer. It is a popular choice for fuel tanks, as evidenced by its widespread use in the market. However, it is challenging to weld, and fabricators may need to seek specialised welding services.
Stainless steel is also a suitable option for custom fuel tanks due to its high resistance to corrosion. While it is more expensive than mild steel, the cost is offset by the absence of expensive coatings required for mild steel. Stainless steel is also a preferable alternative to mild steel because it does not require additional coatings, which may not hold up well over time.
The choice between aluminium and stainless steel depends on various factors, including cost, ease of welding, and the environment in which the fuel tank will be used. Aluminium must be isolated from the steel structure of the car to prevent cathodic corrosion, especially in high-salt environments. This adds to the cost and design complexity.
On the other hand, stainless steel welds can be more brittle than aluminium welds, potentially making them more prone to cracking in high-vibration environments. However, this can be mitigated by careful workmanship and proper welding techniques.
Ultimately, both aluminium and stainless steel offer advantages and considerations for custom fuel tank construction, and the ideal material depends on the specific requirements and constraints of the project.
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Tack welding is important to keep things square
Tack welding is a temporary welding process that involves using low heat and a very short arc to weld metal pieces together before the final welding. It is important to keep things square when tack welding to ensure that the metal parts are aligned correctly and do not move when welding.
When tack welding, it is crucial to make small and hot tacks. This means using a higher temperature than what is typically used for running a bead. By making the tacks real hot and real small, you can ensure that they hold the metal pieces together securely. Additionally, it is recommended to use clamps to bridge the two pieces being tacked, providing extra stability and helping to keep things square.
The sequence of welds also plays a crucial role in keeping things square. It is generally recommended to tack in the middle of the workpiece instead of the corners, as tacking in the corners can cause twisting and pull the pieces out of square. By tacking in the centre, you allow the part to pull itself into square. Planning for warping is also essential; since all tacks will pull to some extent, it is crucial to ensure they pull into square rather than out of square.
Furthermore, the type of metal and its thickness can impact the tack welding process. For instance, thin materials with low melting points, such as aluminium, may require additional wires for tack welding and are more challenging to work with. Common metals used for tack welding include stainless steel, copper, brass, titanium, aluminium, and cast iron. Understanding the characteristics of the metal being used is vital to ensuring successful tack welding and maintaining square alignment.
In conclusion, tack welding is a critical step in the welding process, ensuring proper alignment and preventing movement of metal parts. By using the right techniques, such as making small and hot tacks, utilising clamps, tacking in the centre, and considering the metal type, welders can effectively keep things square during the tack welding process.
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Avoid tank slosh with trap doors or small holes
Tank slosh occurs when the fuel moves around in the tank, starving the fuel pump of fuel. This happens when the vehicle is running low on gas, especially during acceleration and when going around corners. Small fuel tanks don't experience this issue because there is nowhere for the fuel to slosh to. Therefore, the fuel pump pickup remains submerged.
One way to avoid tank slosh is to use trap doors or small holes. Track and race car fuel tanks are often divided into sections or small cells with trap doors or small holes between them. This essentially turns a large fuel tank into several smaller ones. Small holes or hinged doors are drilled onto the bottom of these wall dividers to allow fuel to slowly move between the cells. However, rapid acceleration will not allow much fuel movement at any one time. This method also helps to keep the weight of the fuel in a small area, maintaining the balance of the car.
Trap doors need to be well-sealed to be effective. Poorly implemented trap doors can be counterproductive, as fuel can move in both directions through a known orifice, but only so much is allowed to pass in a given time. This ensures that the general flow over time is towards the pickup. One-way geometries, such as a Tesla valve, can be added to control the direction of fuel flow.
As an alternative to trap doors, some people choose to cut a hole in the floor of their car and drop the fuel pump through the top of the tank. This provides quick access to the pump and avoids the time-consuming process of dropping the tank. However, others disagree with this method, preferring to drop the tank or use a trap door instead of cutting into their car.
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Measure the space and consider fuel lines and vents
When creating a custom fuel tank, the first step is to measure the space where the tank will be placed. This process may be time-consuming, so it is recommended to sketch out a potential design while taking measurements. It is important to consider the space needed for fuel lines, vents, level sensors, mounting straps, and other components.
The most common shape for a fuel tank is rectangular, which makes it easier to fabricate and fit into most spaces. A rectangular tank consists of six sides - the front, back, top, bottom, and left and right sides. When designing a rectangular tank, it is crucial to determine the desired shape and dimensions, especially if the tank needs to fit into a specific space, such as behind the seats of a vehicle.
In addition to the physical measurements of the space, it is important to consider the volume or capacity of the fuel tank. The formula H x W x L x 0.004329 can be used to calculate the tank's fuel capacity based on its height, width, and length. This information will be crucial when designing the tank and ensuring it meets the required specifications.
Another important consideration is the placement of the filler neck, vent, roll-over valve, fuel pickup, and fuel pump. These components need to be included in the design and positioned appropriately. The design should also specify the type of gauges and their corresponding electrical sender mounts, as these can vary depending on the manufacturer. Additionally, the tank's orientation (front, top, etc.) needs to be indicated in the design.
Once the measurements and design are finalized, it is recommended to create a prototype to ensure the tank will fit the intended space. This can be done using cardboard materials, cutting out the pieces according to the design and taping them together. By creating a prototype, one can avoid the costly mistake of discovering that something is missing or that the tank does not fit the allocated space.
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Consider a prototype before cutting metal
When creating a custom fuel tank, it is essential to consider creating a prototype before cutting any metal. This step is crucial, as it allows you to identify any potential issues with your design and ensure that it fits perfectly in the allocated space.
Building a prototype can be done using cardboard or paper materials. First, take precise measurements of the space where the fuel tank will be placed, considering the area needed for fuel pickups, fillers, vents, level sensors, mounting straps, and lines. Then, create a cardboard model of the fuel tank, using the measurements from your plans. Ensure that the prototype includes all the actual pieces you plan to cut from the sheet metal.
Tape the cardboard pieces together according to your design, and test-fit the prototype in the intended space. This process will help you identify any adjustments needed and ensure that your final product will fit seamlessly. It is far easier to make changes at this stage than after cutting metal or welding.
Additionally, consider the issue of "tank slosh." Tank slosh refers to the movement of fuel inside the tank when accelerating or turning, which can starve the fuel pump of fuel if the vehicle is running low. One solution is to divide the tank into smaller sections or cells with trap doors or small holes, preventing rapid fuel movement and ensuring the fuel pump pickup remains submerged. You can incorporate this design feature into your prototype to ensure its effectiveness before finalising your metal cuts.
By creating a prototype, you can refine your design, ensure a proper fit, and avoid costly mistakes. This step may take extra time, but it will ultimately save you from potential headaches and expenses down the line.
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Frequently asked questions
Tank slosh refers to the movement of fuel inside the tank when accelerating or turning. This can starve the fuel pump of fuel. To prevent this, the tank can be divided into smaller sections with trap doors or small holes between them.
Stainless steel, mild steel, and aluminum are all materials that can be used to make a custom fuel tank. Aluminum is lightweight, easy to form, and resistant to corrosion, but it is difficult to weld. Stainless steel is also resistant to corrosion and is easier to weld than aluminum. Mild steel is not recommended due to its susceptibility to corrosion.
The first step is to take measurements of the space where the tank will go and determine the desired shape and dimensions. A prototype can then be created using cardboard to ensure that the design fits the allocated space. Once the prototype is approved, the materials can be cut and welded together.
Rock Valley Antique Auto Parts and KP Fabrication & Welding are two companies that can assist with creating a custom fuel tank. Rock Valley requires a blueprint with specific details such as height, width, length, and additional features. KP Fabrication & Welding provides guidance and offers a range of custom aluminum products.
