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Posted by: phillstek Sep 15 2011, 12:53 AM

Ever since cutting and welding my original tank it had a rust problem. Ultra fine rust particles were constantly being sucked through the lines blocking the fuel sock and despite 3 in-line filters, clogging the jets and giving me the shits.

I know I could have just got a kit and treated it but I kept getting conflicting opinions on whether or not that works.

Checked out the Fuel Safe option and they couldn't modify the bladder for rhd applications so the only bullet proof solution was to make one.

Started by profiling the tank bulkhead and then folding some sheet to suit.

Tank will have internal baffling, swirl sump for future efi conversion and a roll over valve for venting.

Also doing an expansion tank that will mount on the front side of the bulkhead.

Not sure what the exact capacity will be but I reckon it'll be around 60 litres

Here are some progress pictures, all thoughts and comments welcome.

Phil


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Posted by: rick 918-S Sep 15 2011, 03:12 AM

Very nice idea. The only suggestion I have would be to use a "T" dolly in a vise to strike the edges over slightly. Round them over to meet each other. Here's a diagram of what I'm explaining.



Sorry for the crude drawings. But if you can break the corners where they meet they are less likely to warp as you try to weld them. It gives them a nicer round look. Also when butt welding two panels with the kind of heat transfer aluminum has you want to crease the panels like the lower example. This will help the panels stay aligned and make for less work straightening when your done. It gives you a nice crown to fillet.

Posted by: phillstek Oct 10 2011, 02:25 AM

Thanks for the tip rick, although my welder friend managed to keep the distortion under control and apart from a couple ugly, fat-arse welds on the ends, it came out looking pretty good.

The internal pump routes fuel to the expansion/accumulator tank (small tank in pic). The e/a tank will mount up behind the main tank, under the cowl and feed to main pump, breather and charcoal can.

Using flexible stainless lines between the tanks and Tangerine lines through the tunnel.

Trial fitting of the tank went well, it fits like a finger in a place where a finger shouldn't go (polite version of an Australian colloquialism). I will use a piece of conveyor belt rubber under the tank and mount tabs to isolate chassis vibrations and rattles.

We can do more of these if there is any interest. It was made for left or right hand drive cars.

Comments and criticisms welcome.

Phil


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Posted by: URY914 Oct 10 2011, 05:04 AM

How much does it hold?

Posted by: phillstek Oct 10 2011, 05:26 AM

I haven't filled it yet but the estimate is 55-60 litres.

Posted by: Hontec Oct 10 2011, 06:20 AM

Very nice!! did you sump/baffle/foam it by any chance?

Posted by: Series9 Oct 10 2011, 07:01 AM

That's extremely well done. Nice job.

Posted by: Eric_Shea Oct 10 2011, 07:04 AM

Excellent Phil.

Posted by: ptravnic Oct 10 2011, 07:10 AM

Ambitious project - very nicely done.

Posted by: Niklas Oct 10 2011, 07:18 AM

Nice work!!

You should sell them.

Do you make if I order ?
Can you send to sweden ?
Maybe it is to expensive to send to sweden ??

Niklas

Posted by: 76-914 Oct 10 2011, 08:26 AM

No baffles?

Posted by: phillstek Oct 10 2011, 12:55 PM

Thanks for all the positive comments

Hontec, the tank has 2 baffles and a swirl sump but no bladder or foam. By comparison to the work you do, my tank is pretty crude.

Niklas, yes we can make it if you want one. Not sure as to price and I would imagine that shipping from here to Sweden would be prohibitive. It depends on your definition of expensive.

Thanks again to all. I'm glad you guys like it.

Phil

Posted by: wingnut86 Oct 10 2011, 01:07 PM

Phil,

You have to ignore Hontec sometimes.

He's all about the "Bling" factor as we say in Yankee land.

I mean really, green lines in the floor?

He's not even Irish

Excuse the hijack > Image of Hontec when we meet finally

Posted by: JmuRiz Oct 10 2011, 01:11 PM

Very cool...I've always been jealous of those English car guys that have stainless and alumn fuel tanks for good prices on the aftermarket.

Posted by: phillstek Oct 31 2011, 02:02 AM

Tanks for all the positive comments. Trial fitting the new tank revealed a couple of minor clearance issues. Had to modify the filler neck and counter sink the fuel level sender aperture as they just fouled the bonnet when attempting to close it. Other than that it turned out really nice.

Phil


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Posted by: mikea100 Oct 31 2011, 07:56 AM

Great job, Phil. Are you planning on mass producing it? There're many threads on cleaning rusty fuel tanks, but making an new aluminum piece trumps them all. Well done.

Posted by: rwilner Oct 31 2011, 09:16 AM

with this tank in place, can you install the fresh air blower?

Posted by: phillstek Oct 31 2011, 01:11 PM

Blower fits fine but I removed the right-side splitter as that's where I'm locating the expansion/accumulator tank.

Making a tank from scratch was probably 'overkill' but I wanted the fuel system to be as bullet-proof as possible. We can manufacture to order if required but as far as 'mass production', I don't think so. Shipping costs from Australia would be hellishly expensive as well.

Thanks for looking and all the feedback.

Phil