Alloy fuel tank from scratch

**Ozzy27** · 9th April 2010, 21:00

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

**jonbuoy** · 10th April 2010, 06:49

Originally Posted by gatch

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** · 10th April 2010, 07:16

Just a wet rag will do as a heatsink.

Steve

**Blackflagged** · 10th April 2010, 21:35

Originally Posted by meowmix

I know brazing is quite appropriate for alum. These bikes 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** · 11th April 2010, 08:39

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

http://www.youtube.com/results?searc...azing+aluminum

Steve

**jonbuoy** · 11th April 2010, 21:04

Originally Posted by DangerousBastard

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

http://www.youtube.com/results?searc...azing+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** · 11th April 2010, 21:31

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** · 12th April 2010, 00:13

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