Over the course of this project, the fuel tanks have been something I have been pondering how to do. Choices were factory tanks, composite tanks, or build my own aluminum tanks. I gave up on the idea of composite tanks and the factory tanks won’t work with the routing of my control cables so custom aluminum tanks became the default choice. I had already made a wood mock up of the tank so moving forward with a custom tank wasn’t that big of a deal. Problem is ….. I don’t have much experience welding aluminum. I decided to move forward away.
First, I did the research and bought all the necessary parts for the tank. Drains, caps, finger strainers, etc. The EAA books provide great assistance in this area.
Next, patterns to form the aluminum. That proved pretty easy. I made oak patterns to form the aluminum. After one practice piece, I found forming the aluminum to be pretty easy.
I also completed my mock up for the tank. I already had a mock up made when I built the bay and the straps. I needed to widen the mock up and add all the fittings (in wood) to identify placement of all the parts.
About this time, at an EAA meeting, I got the name of a master fabricator and gas aluminum welder in our area. I contacted this guy and arranged to have him build my tanks. Turns out, he has been fabricating Indy cars since the late 1960’s. His aluminum welding is so well known and respected that the NHRA allows his gas welded aluminum tanks on funny cars. All other welding and welders must use Tig or Mig. what a find! His price: less than What a find! I would have paid for factory tanks! So, off I went with the wood mock up, my patterns, and all the parts. I dropped everything off with a hand shake and the idea of “a month or two” for fabrication. Now that’s old school!
I brought everything to the fabricator in September and the tanks were finished in November. They are works of art. The tanks are gas welded .060 aluminum. By gas welding, the tank becomes “one piece” of aluminum. If I need to dimple a weld area, no problem. Gas welded aluminum will not crack like Tig welds. This is the process that custom hot rodeos use to build up the beautiful street rods that we all drool over at car shows. Anyway, the tanks are beautiful and fit perfectly.
Next up: floorboards and assembly of the fuselage.
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