The Gas Tank
Earlier in the week, I posted a different thread trying to decide whether to buy an aluminum cell, or cheap out and buy a plastic one. The concensus at the end of the thread was That I was gonna build one out of steel instead.
I cannot Tig aluminum, my machine won't handle it, and I don't have the experience to make it look decent.
I can mig my ass off though, so I decided to call my steel supply guy and have him cut and bend the necessary pieces out of standard cold rolled mild steel.
I wanted 15 gals. I did some math and figured that it would take a rectangle 10"H x 23L x 17 W to get that volume. So that is what I had him cut.
Unfortunately he was swamped and I didn't get the stuff until yesterday, but I prepped the trunk so I would have that behind me.
(stupid camera. Always has a problem w/ backlight)
What we're seeing here is where I cut out the spare wheel well, and patched in a piece of 18 ga sheetmetal. I hand rolled a 3/8 lip to add structural integrity to the cut out, as I intend to mount the future tank just like they did in the older fords, through the bottom of the trunk floor.
Thursday afternoon I get the call from steel dude, so I go get my junk.
View attachment 187353
A top, bottom, and a folded side Total invested so far........$35.00
So I set out building the thing. It's still 18 ga., so I gotta weld it in sections at a time to keep it from warping.
View attachment 187354
If you'll look closely, you'll see where I started and stopped every weld. I only went about 4" at a time, and then would rotate the box to the next side.
What tha?
When you are concerned that they weld integrity has to be as good as it can get, and you have a damaged eye, sometimes you need a little extra uhhh "magnification".
Whats that doo dad next to the ant burner? It's the bulkhead that I welded to the inside of the tank that will allow me to bolt my fuel pump to the tank wall. Why did I have to make it an "inny" and not just weld some bolts to the out side of the tank wall?
Well, when you have to drop the tank through the floor, the opening is only big enough to allow the tank through it. Any bolts hanging off the wall would not let it slide by.
There now. Glad we got that out of the way.
View attachment 187356
Another shot of the weld quality. I'm pissed that I had to stop and start, otherwise it woulda looked like it was tigged.
The top w/ the sending unit and filler holes reinforced.
View attachment 187358
The "box", Complete and ready for red kote.
Speaking of Red Kote, The more inquisitive of you should be wondering what I'm gonna do to keep a mild steel box from rusting like mad inside, especially now that all gas contains 10% ethanol.
Well enter Red Kote. A gas tank sealer that effectively coats every inch of the inside surface to seal it and prevent any rust. Additionally, it will seal small pin holes up to 1/32" should I have any from the welding process.
View attachment 187359
And pinholes?
View attachment 187360
Just one.
This stuff oozes out until it clots like a cut. Obviously, I had the tank upside down from this picture, but its already on it's way to drying, so I'm not gonna fk with it.
The total I have in the tank is 60.00. I reused the sender out of the factory tank, and I had to custom make the filler neck anyway, so I think I'm in it pretty decent. I'll paint it and hang it tomorrow, and the fuel system will be done.
Earlier in the week, I posted a different thread trying to decide whether to buy an aluminum cell, or cheap out and buy a plastic one. The concensus at the end of the thread was That I was gonna build one out of steel instead.
I cannot Tig aluminum, my machine won't handle it, and I don't have the experience to make it look decent.
I can mig my ass off though, so I decided to call my steel supply guy and have him cut and bend the necessary pieces out of standard cold rolled mild steel.
I wanted 15 gals. I did some math and figured that it would take a rectangle 10"H x 23L x 17 W to get that volume. So that is what I had him cut.
Unfortunately he was swamped and I didn't get the stuff until yesterday, but I prepped the trunk so I would have that behind me.
(stupid camera. Always has a problem w/ backlight)
What we're seeing here is where I cut out the spare wheel well, and patched in a piece of 18 ga sheetmetal. I hand rolled a 3/8 lip to add structural integrity to the cut out, as I intend to mount the future tank just like they did in the older fords, through the bottom of the trunk floor.
Thursday afternoon I get the call from steel dude, so I go get my junk.
View attachment 187353
A top, bottom, and a folded side Total invested so far........$35.00
So I set out building the thing. It's still 18 ga., so I gotta weld it in sections at a time to keep it from warping.
View attachment 187354
If you'll look closely, you'll see where I started and stopped every weld. I only went about 4" at a time, and then would rotate the box to the next side.
What tha?
When you are concerned that they weld integrity has to be as good as it can get, and you have a damaged eye, sometimes you need a little extra uhhh "magnification".
Whats that doo dad next to the ant burner? It's the bulkhead that I welded to the inside of the tank that will allow me to bolt my fuel pump to the tank wall. Why did I have to make it an "inny" and not just weld some bolts to the out side of the tank wall?
Well, when you have to drop the tank through the floor, the opening is only big enough to allow the tank through it. Any bolts hanging off the wall would not let it slide by.
There now. Glad we got that out of the way.
View attachment 187356
Another shot of the weld quality. I'm pissed that I had to stop and start, otherwise it woulda looked like it was tigged.
The top w/ the sending unit and filler holes reinforced.
View attachment 187358
The "box", Complete and ready for red kote.
Speaking of Red Kote, The more inquisitive of you should be wondering what I'm gonna do to keep a mild steel box from rusting like mad inside, especially now that all gas contains 10% ethanol.
Well enter Red Kote. A gas tank sealer that effectively coats every inch of the inside surface to seal it and prevent any rust. Additionally, it will seal small pin holes up to 1/32" should I have any from the welding process.
View attachment 187359
And pinholes?
View attachment 187360
Just one.
This stuff oozes out until it clots like a cut. Obviously, I had the tank upside down from this picture, but its already on it's way to drying, so I'm not gonna fk with it.
The total I have in the tank is 60.00. I reused the sender out of the factory tank, and I had to custom make the filler neck anyway, so I think I'm in it pretty decent. I'll paint it and hang it tomorrow, and the fuel system will be done.
Building the gas tank was a welcome diversion from sanding. I have the entire passenger side to finish. It is untouched. The painter called me on Saturday to see where I was progress wise, and I told him a month of Sundays away.
