aluminium fuel cell

[benno440]

Guys,
I am going to build a custom fuel tank for my charger out of aluminium.

Reasons for doing this:

* want a bigger capacity tank
* weight saving
* looks
* eliminate fuel slosh
* get an accurate fuel level and be gone with the inferior dodge sending unit
* a properly vented tank

Want some ideas on how to do it please.
I am going to build it so it looks similar and sits in same place as the standard tank (68 charger)

going to install a autometer fuel sending unit
I will need return line fitting, fuel pickup fitting, and rollover vent

my questions are:

the rollover vent goes on top of tank am I right?
fuel return also goes on top of tank?
fuel pickup I was going to put a small sump on tank at the bottom and a fitting for the fuel pickup so the fuel does not have to run up a tube inside the tank to the top, is this okay to do?
Now how does the tank get vented? is this done by the rollover vent or do I need something else to vent the tank?

 

[67 B-body]

I would just copy a fuel cell setup and simply change the shape as needed....
Mine has -AN fittings at each connection, and the sump area has two itself for additional fuel source needs like Nitrous....
You could make two end pieces (like a wing rib) and then use sheet aluminum to wrap around forming a more stock shape tank, weld up the ends and one joining seam. Then you could cut out your sump area and box it off with your fittings included... If your going internal pump setup,,, someone has a pump conversion for a drop in arrangement....
The vent is a roll over setup... You have to have a way to keep fuel from spilling out if the car goes on its top... Then you should have a return fitting on the top of the cell....

 

[Theslo1]

From my understanding, you only need one vent of appropriate size. You can have more if you like, but they all should have a rollover protection valve. My metalworking book suggests making a cardboard tank first because its easier and cheaper to make changes to paper than your expensive metal. One other thing I've heard is the return line should not be near the fuel pickup, it causes the fuel to get air in it. I hope your welds are perfect, making tanks is one of the hardest things to do, the smallest pinhole will cause headaches. When I built the steel gas tank for one of my projects I welded a fitting on so I could pressure test it with only 3-4 psi and soapy water. I didn't feel comfortable with more than that, pressure vessels are dangerous, I've seen first hand when 45psi was released suddenly near me, it was scarey. I welded my tank then pressure tested it and marked any leaks. Then I released the pressure and tried to close up the pinholes. I guess a gastank sealant could be used, but I didn't want to go that route. Good luck, don't forget to post picks of progress and the finished product.

 

[benno440]

my welds are pretty good thanks bud, im an engineer boilermaker and master TIG welder (so to speak), I have heard 2-3psi is plenty for a fuel tank, thanks for your input. I built that slant 6 intake manifold a while back, take a looksy for the post.

will post pics when done

thanks guys, I think I have it all planned out now