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  1. #1
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    Default Making a fuel tank?

    Ideally the fuel tank(s) would be situated under the seat - providing seat support, keeping the CoG in the middle and won't move during use, neater finish.



    I was thinking an aluminium sheet bent and welded at each end to form a long thin one.



    It would have 2 compartments inside running the long way, so filling/take off for both compartments are at one end. This means I can effectively have the seat resting on the top of the tank, and the filling cap can be at the end where the seat rises up with the handlebars.



    I have emailed a few companies/people who do sheet metal fuel tanks, and they are quoting from £180 - £250.



    Does anyone here have expereince making one / can advise me on making one myself / sell me one cheaper / make one cheaper at all?



    I have expereince welding steel, but never aluminium. It looks difficult, but would be cheaper if it came off well!


  2. #2
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    Default Re: Making a fuel tank?

    Toby,

    If you want to weld aluminium, then idealy you should use an AC/DC tig machine. You can use the handy migs with special flux coated wire, you can buy it in Halfords. However, i have never found it to be very successful. The one thing is the ally must be clean! Good luck.

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    Default Re: Making a fuel tank?

    welding sheet ally edge to egde with a handy mig, will look rougher than a sack of knackers, and i doubt you will get it fuel tight, on the first second or third try!

    assuming you dont have access to a sheet metal giloteen and or press brake, therefore an ally tank cut with a jig saw and folded by hand or on a box and pan folder will be rough as it gets! you also have to think about heat distortion!



    250 quid is extremly high price for a fuel tank, used to make them where i work, and sell for around 100 quid, this was based on 20 quids worth of material (excluding fittings) and then 2 hours labour!



    unless you have access to proper cutting equipment, decent Tig welder etc i would not even contemplate making a ally tank!

  4. #4
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    Default Re: Making a fuel tank?

    i appear to have been in france earlier today! Odd.

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    Default Re: Making a fuel tank?

    Quote Originally Posted by dangerman
    i appear to have been in france earlier today! Odd.


    It's a secret thing we're working on behind the scenes here at Hover Central, don't be alarmed, but DO buy a phrase book

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    Default Re: Making a fuel tank?

    I've made aircraft fuel tanks from alloy, using pop rivets and sealant. It's a very well proven technique - hundreds of aircraft are flying around with tanks made this way.



    You just bend the sheet up (making sure that the last panel to be fitted is big enough to get your hands in) with flanges about 1/2" wide or so where edges join. Pop rivet the flanges together, then liberally apply 2 pack fuel resistant sealant (the best stuff is PR1422, see here: http://www.lasaero.com/article/a-pr1422).



    The final panel is best fitted "wet" with sealed pop rivets (ones with no hole right through) and a liberal smearing of sealant on the mating faces.



    The sealant is horrible stuff, but is exceptionally good at both bonding the tank together and sealing. At least one aircraft has it's wing skins just glued on with this sealant.



    Jeremy

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    Default Re: Making a fuel tank?

    i think dangerman has hit the nail on the head.



    i have access to a MIG and a jigsaw.



    This is going to be a problem...

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    Default Re: Making a fuel tank?

    I think I foudn the solution



    http://www.dureflex.co.uk/



    Make custom plastic fuel tanks - rigid and flexible!



    they seem to make skirt segments too.



    Please forgive me if this is old news

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