Mercedes Mullins
Building a fuel tank from a can is a challenging task that requires careful planning and execution. It involves designing a prototype, selecting appropriate materials, and ensuring safety measures to mitigate the risks associated with flammable gases. One crucial step is to create a cardboard mock-up of the tank to ensure a proper fit and understand the interaction with other vehicle components. The choice of materials is essential, with options including mild steel, which requires coating to prevent corrosion, or stainless steel, which offers higher corrosion resistance and welding ease. Safety considerations include positioning the tank away from the exhaust to avoid heat issues and incorporating baffles and sumps to control fuel movement and prevent starvation of the engine. Building a fuel tank demands a meticulous approach to ensure functionality and safety.
| Characteristics | Values |
|---|---|
| Materials | Cardboard, sheet metal, stainless steel, mild steel |
| Fuel tank design | Baffles, sumps, fuel inlet, outlet, filler neck, vent, roll-over valve, fuel pick-up, FI pump |
| Fuel tank location | Away from the exhaust, under the tub |
| Fuel tank construction | Tack welding, clamping, shearing |
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What You'll Learn
Create a cardboard mock-up and design
Creating a cardboard mock-up of your fuel tank is a crucial step in the design process. It allows you to test the fit and functionality of your tank before committing to more expensive and challenging materials. Cardboard is versatile and easily workable, making it ideal for prototyping. Here's a step-by-step guide to creating a cardboard mock-up and design for your fuel tank:
Step 1: Measurements and Planning
Start by taking precise measurements of the space where you plan to place your fuel tank. Consider the surrounding components, such as the exhaust, rear end, and cross members. Ensure you allocate space for fuel pick-ups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. Draw your design on paper, including all the necessary measurements.
Step 2: Cardboard Mock-Up Construction
Using cardboard, create an exact replica of your fuel tank based on your design. Cut, fold, and tape the cardboard pieces together to form the tank's structure. Ensure that the cardboard mock-up represents the actual pieces you will cut out of sheet metal for your final tank. This step allows you to test the fit and make any necessary adjustments to your design.
Step 3: Test Fitting
Once you have constructed your cardboard mock-up, it's time to test its fit in the intended space. Place the mock-up in the vehicle and ensure it fits securely and doesn't interfere with other components. This step helps you identify any design flaws or necessary modifications.
Step 4: Refinement and Finalization
If adjustments are needed, modify your cardboard mock-up accordingly and repeat the test-fitting process until you achieve the perfect fit. Once you are satisfied with the mock-up's performance and placement, you can use it as a template for your final fuel tank construction. Disassemble the mock-up carefully, and use its pieces as patterns to replicate onto your chosen metal.
Creating a cardboard mock-up is a cost-effective and efficient way to refine your fuel tank design. It allows for design iterations and ensures that your final product will be functional and well-fitted to your vehicle. Remember to take your time, be precise with your measurements, and don't hesitate to make changes to your design as needed.
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Choose your material
The first step in building a fuel tank is to choose the material. This is important because the material will determine the durability, safety, and overall quality of your fuel tank. Here are some factors to consider when choosing your material:
- Metal Type: Metals like steel and aluminium are commonly used for fuel tanks. Steel is strong and durable but requires a coating to prevent corrosion. Stainless steel, in particular, is highly resistant to corrosion and relatively easy to weld. Aluminium is also a good option as it is lightweight and corrosion-resistant, but it may be more expensive and require specialised welding techniques.
- Thickness and Size: Consider the thickness of the material, which will impact the overall durability and weight of the fuel tank. Thicker materials may provide more strength but will also add weight. Determine the size requirements for your fuel tank, ensuring it fits the intended space and meets your fuel capacity needs.
- Ease of Fabrication: Some materials are easier to work with than others. Consider the tools and skills you have available for cutting, shaping, and welding the material. For example, sheet metal is readily available and can be easily cut and welded, making it a good choice for a DIY fuel tank project.
- Safety and Regulations: Keep in mind any safety standards and regulations that may apply to fuel tanks, especially if they are for automotive use. This could include requirements for coatings, baffles, sumps, and ventilation systems to prevent fuel leaks and reduce the risk of combustion.
Once you've chosen your material, you can start designing your fuel tank, keeping in mind the unique properties and requirements of the material. Remember that creating a fuel tank requires careful planning and execution to ensure a safe and functional final product.
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Prepare the material
Before you start building your fuel tank, it is important to prepare the materials. The first step is to decide on the type of material you will use. Mild steel is an option, but it is corrosive, so you will need to coat the inside and outside of the tank. Stainless steel is another option, which is highly resistant to corrosion and not too difficult to weld. It is more expensive than mild steel, but you will save money in the long run as you won't need to purchase expensive coatings.
Once you have decided on the material, you will need to get the pieces cut to size. If you are using stainless steel, you can use 14-gauge stainless steel, which is the standard for fuel tank construction. You will need to cut the pieces into the shape required for your design. For example, if you are making a rectangular tank, you will need two C-shaped pieces that fit together. You can get these pieces cut at any sheet metal shop, and it should be relatively inexpensive.
In addition to the metal pieces, you will also need to prepare any additional components, such as a sump and baffles. A sump is a crucial component of a fuel tank, as it ensures that the fuel stays near the pickup, preventing the engine from stalling. You can purchase a sump separately or cut it into the bottom of your tank. Baffles are also important, as they help to control the movement of fuel within the tank, especially during rapid acceleration.
Before you begin assembling your tank, it is a good idea to create a mock-up using cardboard. This will allow you to test the fit and ensure that your design works with the other components of your vehicle, such as the exhaust. Create a cardboard model that represents the actual pieces you will use to construct your tank. This will help you identify any potential issues before you start welding.
Finally, if you are planning to have your tank professionally made, you will need to supply the manufacturer with a detailed blueprint. This should include the height, width, and length of the tank, as well as the location of components such as the filler neck, vent, and fuel pickup. The manufacturer will review your design and may suggest changes before providing a final confirmation.
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Assemble the tank
To assemble the tank, you will need to decide on the material you want to use. Stainless steel is a great option as it is highly resistant to corrosion and not terribly difficult to weld. However, it is more expensive than mild steel. If you choose mild steel, remember that it is corrosive, so you will need to coat the inside and outside of the tank.
Once you have your materials, you can start constructing the tank. If you're welding the tank together, make sure you clamp it in as many places as possible before you start. Tack welding in multiple places will help keep things square and prevent movement when you go back to do the final welds. Move around and weld different areas of the tank, don't just focus on one side. Tack the entire fuel tank together before any final welding is done. Even when final welding, weld a small section of one side and then move to another side.
If you want to test your design before you start assembling, you can create a cardboard mock-up of the tank and fit it to the space you intend to place the real one. This way, you can figure out how the rest of the vehicle's parts, such as the exhaust, might interact with the tank's location.
When assembling the tank, consider adding baffles and a sump to prevent fuel from getting away from the pickup and causing the engine to stall. You can also add a fuel pump at the bottom with angled blocks to guide the liquid flow, ensuring the fuel pump pickup remains submerged. Small holes or hinged doors can be drilled onto the bottom of wall dividers to allow fuel to move slowly between the cells.
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Test for leaks
Testing for leaks is crucial to ensure the safety and effectiveness of your fuel tank. Here are some detailed steps to guide you through the process:
Prepare the Tank
Before starting the leak test, ensure that your fuel tank is properly constructed and clamped together, as per the previous instructions. Clean the tank and its surrounding area to create a safe workspace. It is important to note that different specifications and standards, such as UL specs, may require specific testing methods, pressures, and even destructive tests prior to production building. Be sure to consult relevant guidelines for your tank.
Pressure Testing
One common method to test for leaks is by pressuring the tank with air. It is recommended to not exceed 5 PSI max when conducting this test. Ensure that the air is filtered to eliminate moisture. You can use a bicycle pump to pressurize the tank through a Schrader valve.
Soap and Bubble Solution
Apply a soap and bubble solution, or a soap-water mixture, onto the tank and look for the formation of bubbles. Bubbles indicate a leak, as air escapes through the opening. This method may not be effective in finding weeping rivets, so it is recommended to combine it with other testing methods.
Manometer Measurement
A manometer can be used to measure the pressure inside the tank. Hook up the manometer to the fuel tank and pump air until the desired pressure is reached. For example, a differential of 30" of water pressure, which equates to approximately 1 PSI at high altitudes.
Fuel Immersion Test
Fill the tank with fuel, such as 100LL, and let it sit for several days. Check for fuel stains or traces of fuel on the outside of the tank, which indicate a leak. This method accounts for fuel potentially seeping through without a loss of air pressure. Use caution when handling fuel and fumes during this test.
Helium Gas Test
Helium gas can be used to pressure the tank, as it has the ability to escape through smaller holes. This method was mentioned in a discussion about testing fabricated tanks built into small ships and tug boats.
Remember to always prioritize safety when working with flammable materials and pressurized tanks. Conduct these tests in a well-ventilated area and follow relevant guidelines and regulations.
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Frequently asked questions
The first step is to create a cardboard mock-up of the tank and fit it to the space you intend to have the real one occupy. This will allow you to figure out how the rest of the vehicle's parts, such as the exhaust, will interact with the tank's location.
The next step is to create a design on paper. Take all your measurements and construct a cardboard model of the tank. Be sure that the cardboard represents the actual pieces you will cut out of the sheet metal to construct your tank.
Mild steel and stainless steel are two commonly used materials for making fuel tanks. Stainless steel is highly resistant to corrosion and not terribly difficult to weld. While mild steel is corrosive, so you will need to coat the inside and outside of the tank.
It is important to consider the location of the tank to ensure it doesn't get cooked by the exhaust. Additionally, you should think about the inclusion of baffles and a sump to prevent fuel from getting away from the pickup and causing the engine to stall.
Yes, Rock Valley Antique Auto Parts in Stillman Valley, Illinois, has been building stainless steel gas tanks since 1981. They can create a custom tank based on your provided blueprint, which includes the height, width, length, and other specifications.
