Author Topic: Ok so I am gonna make a fuel tank. (Read 2591 times)

4RunnerChevy · « **on:** Jun 18, 2009, 12:19:58 PM »

I have a bunch of aluminum, so I am gonna make a tank. I want the tank to fit a certain spot, and that is the reason not to buy one. I got the welding, pump, and fuel fitting part down. I am unsure of baffles ? Does anyone have links or picks of what they did when building a custom tank. I can go either way, chevy drop in pump unit or external pump, and I'll be using the Toyota sending unit.

Thanks

pumkin toy · « **Reply #1 on:** Jun 18, 2009, 04:30:29 PM »

here is a link to my fuel tank build. i built mine out of stainless. there are a few pics of the baffles towards the bottom of the page. i just took two sheets of stainless and punched a bunch of holes in them, then tacked em in place inside. it was pretty simple, seems to be working fine. just make sure your baffles have an open area at the very bottom of the tank so fuel has an opening to pass through when your fuel level gets low. http://board.marlincrawler.com/index.php?topic=54076.60

4RunnerChevy · « **Reply #2 on:** Jun 18, 2009, 05:46:59 PM »

Thanks, any more input ?

Bazzi · « **Reply #3 on:** Jun 18, 2009, 06:48:03 PM »

just subscribing to this... cause I will be doing this soon

4RunnerChevy · « **Reply #4 on:** Jun 18, 2009, 08:27:28 PM »

Quote from: Bazzi on Jun 18, 2009, 06:48:03 PM

just subscribing to this... cause I will be doing this soon

I'll have pics and keep it updated. I'll start up the plasma on Sat. and start cutting. Still working on the Baffle thing. The tank will be 24x20x10 (20G) and roughly 18-19 gallons due to a slight angle in the back.

This whole project will allow me to put at least one seat back in the rear of my runner. Yay.

4RunnerChevy · « **Reply #5 on:** Jun 20, 2009, 04:06:45 PM »

Ok, cut the sheets with the plasma today. The tank will be 26x17x11 to still give me roughly 20 gallons and be able to use what I have laying around. I'll de-burr them tomarrow and hopefully get the bottom all tacked up

.

pumkin toy · « **Reply #6 on:** Jun 21, 2009, 08:30:11 AM »

good deal man! keep it up!

Bazzi · « **Reply #7 on:** Jun 21, 2009, 01:45:20 PM »

you are using aluminium. how thick? I have been thinking about the same thing, just was planning to use normal steel... just question about how thick..

jimbo74 · « **Reply #8 on:** Jun 21, 2009, 02:07:11 PM »

rednecknatureboy · « **Reply #9 on:** Jun 21, 2009, 02:37:49 PM »

4RunnerChevy · « **Reply #10 on:** Jun 21, 2009, 03:21:38 PM »

Ok here we go.. The aluminum is treadplate .105 at its thinnest, this is the size (from my research) that most tanks are made of. The baffles will really give it its strength. The measurements are posted prior. I started welding the tub today.

I was wondering if anyone had a spare sending unit from a truck or runner. I have one, but its in my runner and I don't want to remove it for mockup. I would give one back in return, after I make the change.

Anyway some pics

Next is to make the baffles, and figure where my fill, pickup/return and vent are gonna be placed. I want to hook it up to my existing fill spout/cap, so I will use fuel safe 2" hose. I will make a neck for the tank to connect the hose.

Should I use foam, on the bottom ?
Anything I am missing ?

Kevin

4RunnerChevy · « **Reply #11 on:** Jun 29, 2009, 03:57:38 PM »

Some pics of the lid, I gotta still weld the lid to the tank and weld mounting tabs. Then I will pressure test it then do the fill spout.

Parts before weld

Underside of top with sending unit bung (center), fuel pickup/return/vent bung (square), and fuel door with larger opening.

Top of tank

emsvitil · « **Reply #12 on:** Jun 29, 2009, 04:49:11 PM »

You need something like this in the middle:

The inner tank is open at top, something like a tall pan.

When level, fuel flows in thru the tubes.

But when not level, the fuel stays in the inner tank and doesn't flow out the tubes to the main tank.

You can arrange for either left/right or fore/aft (or both)

Slolyfe · « **Reply #13 on:** Jun 29, 2009, 05:36:10 PM »

How many gallons is it going to hold? Looks good!

pumkin toy · « **Reply #14 on:** Jun 29, 2009, 07:13:00 PM »

your welds look good! everything is coming alone pretty smooth

SJyota · « **Reply #15 on:** Jun 29, 2009, 07:16:30 PM »

Good Job on the tank

4RunnerChevy · « **Reply #16 on:** Jun 30, 2009, 04:34:22 AM »

Tank is 20 gallons, and I am still working out the baffles.

4RunnerChevy · « **Reply #17 on:** Jun 30, 2009, 05:31:39 PM »

No pics yet, but tank is welded and presure tested. I have a few leaks, under pressure test, but those are fixed. That much weld with aluminum, theres bound to be a flaw, good news is that fixing flaws in aluminum is easy. Next is to weld angle along the bottom for mounting the SOB.

Pics soon

4RunnerChevy · « **Reply #18 on:** Jul 07, 2009, 06:15:13 PM »

Done

Now for the install.

pumkin toy · « **Reply #19 on:** Jul 07, 2009, 09:37:22 PM »

nice! tank looks good. its alot more fancy than mine! lol

Slolyfe · « **Reply #20 on:** Jul 07, 2009, 09:53:12 PM »

Nice going! looks great!

burnyota · « **Reply #21 on:** Jul 09, 2009, 12:48:24 PM »

Not bad..welds look good. The only thing that you might have wanted to consider is pan ends. This will give greater strength for the welding, rather than just a straight but as you have done, and make a hell of a strong tank. We build a lot of fuel cells at my work, and supply a bunch of mfg's parts as well, like Gen-Rite 4x4. Baffles are important, the easiest is to just clip the corners.

4RunnerChevy · « **Reply #22 on:** Jul 09, 2009, 07:46:25 PM »

As far as Baffles I just clipped corners. I ran it today and it seems just fine, I ran it down hills and up on a low tank and all seems good. Pics soon

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