Aluminium fuel tank for stock location., Trial fit and some modifications Options

[phillstek]

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

[rick 918-S]

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. (IMG:style_emoticons/default/welder.gif)