Fuel tank build

[wingtime]

My fuel original tank had some deep pits in it.  While it wasn't leaking yet I figured I'd play it safe and replace it.  I had quote of $750 for a new tank shipped to my door.  That sounded steep so I decided to make my own.  A friend of mine is a marine welder and he builds everything from T-tops to fuel tanks.  He said he'd help me build one.  So I ordered a 4' x 12' sheet of 1/8" 5052 aluminum for $126.  I took a drawing and the aluminum to a machine shop that we use at work and they sheared and bent the parts to size for $125.  I bought a weld in bung for $8 and a fuel pick up tube for $18.99.  Last night we spent five hours welding and pressure testing my new tank.  I'm thrilled with the results.  Here's some pics:

























I can't wait to get this baby mounted!

[Capt. Bob]

Looks slick WT    
Are you going to coat the outside with anything?

[CDUX]

Very nice and very interesting, as after pulling my tank last week, I find myself in the same situation.

[wingtime]

No I'm not planning on coating it with anything.  The goal is to keep water from getting trapped in contact with the tank.  This means no foam, paint, coatings etc.  I will 5200 some 3/4" starboard strips to the bottom of the tank to keep it up off the bottom of the coffin.  The idea is to have good airflow around the tank so that any water that gets on it can evaporate.  Any water that is trapped against the tank will cause cavitation pitting.  Besides the original tank lasted 28 years and I think it would have lasted longer if some bone head PO hadn't used foam tape under the straps and allowed the cover to leak.

[LilRichard]

Awesome!

I wish I could weld aluminum... need a tig, and some lessons.

 :(

[slvrlng]

Hey Rich you buy it and I'll teach you while you build my new tank!

[LilRichard]

Hey Rich you buy it and I'll teach you while you build my new tank!

LOL.

 :afro:

[GarrettS]

Nice work! What is the capacity of new tank?

[wingtime]

If the tank was completely filled with fuel it will hold 75 gallons.  Since the fill tube is in the middle of the tank and it sits on a slight angle I doubt I would be able to completely fill it.   I'm going to need to get a loan just to fill it anyways!  

[wingtime]

some more project pics:

Bottom of the tank with 3/4" starboard runners glued on with 5200.  The idea here is to keep the tank up off the bottom of the coffin to prevent water from getting trapped against the tank.  This will hopefully allow airflow around the tank preventing cavitation pitting from prolonged contact with water.


Installed in the boat: