Alloy fuel tank from scratch

[CookMySock]

Anyone thought of making an alloy fuel tank from scratch?

Nothing too complicated, perhaps ;

<img src="http://www.fahrtbier.de/wp-content/uploads/2009/02/horex-cafe-racer.jpg" width="480" height="320">
<img src="http://www.eurospares.com/graphics/carlyam3.jpg">
<img src="http://i.ytimg.com/vi/Quy4HEBBhJ0/0.jpg">

I bet its loads more complex than I imagine, but i can't the the idea out of my head. Mock it up in card, then in really thin alloy sheet, then the real thing? Alloy braze it instead of TIG weld?

Why not?

Steve


Steve

[imdying]

Yeah, loads more complex. Check out the curves on that second one, all going in multiple directions at once... that'd feck with ya sanity :D

[CookMySock]

Ah yeah it'd be an acquired skill to do the compound bits, with some expensive rolling gear as well I think.

Steve

[pete376403]

Tank makers roll the sheets into shape using a wheeling machine (aka english wheel). Saw a video of Jesse James (chopper builder, not the train robber) using one to make a tank out of copper and he made a very nice job using just the wheel and really basic hand tools (leather bag, wooden mallet). It's an art form.

http://en.wikipedia.org/wiki/English_Wheel

[Motu]

They are not made in one piece,the curves are broken down onto what can be made,and then welded together.

[jellywrestler]

or you could try a whole bike, main 'tank' portion is 3mm aluminium!

[CookMySock]

They are not made in one piece,the curves are broken down onto what can be made,and then welded together.I hadn't heard that before, but I assumed it was the case.

I assume also, the top is made separate from the base, and they are brazed or welded together.

It seems aluminium could be brazed easily with an air/propane torch.


Steve

[meowmix]

I know brazing is quite appropriate for alum. These bikes (http://www.chabottengineering.com/motorcycle.html) are a great example of what you can do with alloy by hand IMO.

[Sensei]

Just finished making a 25 Litre Alloy tank with internal baffling for a MR2 Supercharged Race car . Used my 250DX Miller HF pulse TIG to weld it all togther took 2 days to complete

[CookMySock]

250DX Miller HF pulse TIGNice. They make such a yummy weld.

Steve

[Blackflagged]

Yep thought about it! Making a mold, etc etc. Apparently some pros just beat them to shape on a bean bag. Must be simpler shapes. On a modern FI bike the base can be the most complex part.
I guess you have seen Beater Tanks in Japan. Nice!
If your after a classic, have a look here http://www.thetankshop.com/
Been some major explosions with carbon tanks, hence not allowed on the road. Aluminiums good, light and does not spark.
I see the 1198r ducati is coming out with a aluminium tank, ... back to the future!

Ended up acquiring the one below in case i do a classic special. But still like to have ago at making one.

[imdying]

Been some major explosions with carbon tanks, hence not allowed on the road.Anyone tell the 888SP owners?

[Brian d marge]

I have got a how to video by carvell ( top fella)

I tried a simple number plate

I will do over time and buy one , thats all I have to say on that matter

Stephen

[jonbuoy]

Braizing an ally tank will be tricky, problem I had with ally and the propane method is the whole work piece ends up at the flow temperature of the braize rods, you get a lot of distortion and you will find your work comes undone as the parts you previously braized come unstuck. Not to mention that when its starts to flow its a little uncontrollable. I tried making a small oil tank - after wasting a few days and some materials I gave up. ^Brians^ got the right idea - put in some extra hours at work and buy one or make a fibreglass tank.

[gatch]

Braizing an ally tank will be tricky, problem I had with ally and the propane method is the whole work piece ends up at the flow temperature of the braize rods, you get a lot of distortion and you will find your work comes undone as the parts you previously braized come unstuck. Not to mention that when its starts to flow its a little uncontrollable. I tried making a small oil tank - after wasting a few days and some materials I gave up. ^Brians^ got the right idea - put in some extra hours at work and buy one or make a fibreglass tank.

For the home handy man, unless you are really handy with a gas plant, ally might be a bit much.

If you have some bits of copper lying around you can smash together a bunch of heatsinks.

Or if you are a cashed up handy man and can afford a nice hf ac tig...

[Ozzy27]

This is worth a read
http://www.eurospares.com/frame7.htm
Always thought of having a go myself at some point.

[jonbuoy]

For the home handy man, unless you are really handy with a gas plant, ally might be a bit much.

If you have some bits of copper lying around you can smash together a bunch of heatsinks.

Or if you are a cashed up handy man and can afford a nice hf ac tig...

Yeah quality welding is a bit of an art even if I had top of the range kit my welds would still look like arse. The only budget way out might be to cut and form the pieces and get a pro to glue them together.

[CookMySock]

Just a wet rag will do as a heatsink.

Steve

[Blackflagged]

I know brazing is quite appropriate for alum. These bikes (http://www.chabottengineering.com/motorcycle.html) are a great example of what you can do with alloy by hand IMO.

Brazings best for lap joints. Not very good for butt joints. In fact it will crack.You can gas weld Aluminium, but it`s a bit of an Art, especially that thin.
If your not so good at welding. Just make it and get someone to Tig weld it.

[CookMySock]

Theres lots of youtube about brazing aluminium. Doesn't look too difficult.

http://www.youtube.com/results?search_query=brazing+aluminum


Steve

[jonbuoy]

Theres lots of youtube about brazing aluminium. Doesn't look too difficult.

http://www.youtube.com/results?search_query=brazing+aluminum


Steve

Have a go and post your results, you will need a very wet rag to keep thin aluminum cool clamping is tricky without being able to tack anything in place. I would also be wary of the strength of the joint you don´t want a full tank fatiguing and splitting open on you on the road.

[AllanB]

Thought about it. Just need the project bike to go with the tank!

I've a bit of alloy in the shed waiting for winter and a bit of time for me to beat it into a small screen.

I've made heat shields etc from alloy - it is very easy to form.

Without checking I suspect the tanks actually use a minimum sheet thickness of a couple of mm as you require a good bit of meat to weld the joins and then grind them down to a seamless finish. Plus the shaping will thin out the alloy on curves etc.

As far as welding a tank - unless you are skilled with a Tig pass it on to a expert - and get the finished product pressure tested before filling it with petrol!

I've a DVD at home of the Biker Build Off series and there is a Aussie builder who forms all bodywork in alloy from scratch - he pre made wooden dummies first and beat the alloy around them, joining pieces as required. Lots of work but very impressive.

[pete376403]

Years ago at tech I recall doing gas aluminium welding where the filler rod was hollow and contained the flux. Did some fairly good welds with that on quite thin sheet

[doc]

Thought about it. Just need the project bike to go with the tank!

I've a bit of alloy in the shed waiting for winter and a bit of time

Well here is an idea

[CookMySock]

Well here is an ideaYeah, one of those! :niceone:

Steve