Gas Tank For Obsolete Truck

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I just found an old thread elsewhere about welding gas tanks, I've got plenty of stories to tell. At present though, I have something related, but a little different on my mind. I have a 1956 Dodge Power Wagon, these things are amazing! Mine has PTO winches front and rear, The geometry was a little challenging, I added a dump body that works from the rear winch. They were available in 8700 lb or 9500 lbs mine is the double frame 9500.Now the challenge: A PTO shaft occupies the space where the gas tank should be. At the time the need was now so I called the local steel supplier asking for a piece of 12" square tube 1/4" wall. All I owned at the time was AC stick. I welded in 1/4" ends and brazed in fittings. The tank is small (8 or 9 gallons), and it produces rust causing the filter to need annual replacement. I want to make a new one of 6061 Aluminum, I want durability. Does anyone have any suggestions?
Reply:Buy a plastic one and make it work. Too many blanks in between bud!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I can't find one that fits. If I shape it right I can make it work. I think a nice aluminum one would keep my fuel clean, and built to shape, double tank capacity. As is I have no gas gauge and need to fill each time I use the truck. Not the end of the world, not my daily driver, but a nuisance. I'm not absolutely confident i'm up to porosity free seams, I'll pressure test to be sure.Are weld in aluminum fittings available, or must I make them from billets? Are gas gauge sending units available?
Reply:Keep one thing in mind. Free surface liquid sloshing around in a tank can and will beat the snot out of it. That's why most larger fuel tanks contain baffles to slow down or limit sloshing. It's not so bad when the tank is full, but when 1/2 empty, especially with a tank design that allows the fuel to pick up some momentum,  fuel movement can be significant..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Build your aluminum tank and put a few baffles inside it. Have the 3003 or 5052 broke so you only have to weld the top and sides, there will be two pieces that fit together like a glove. Most of the tank i have done are .120 thick even a few heavy ones 3/16". Yes you can but weld in bungs already threaded or you can get a 1" solid stock 6061 and tap them yourself. Yes you can get a in exspensive sending unit that can be adjusted for your tank height, look in jegs or speedway motors for it. Let me know if you need anymore help!
Reply:McMaster-Carr should have everything you'll need to build an aluminum fuel tank. http://www.mcmaster.com/# Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Kkustoms is correct; make the tank out of 5052. It is a good compromise between outright strength, and yet it forms and can be bent without cracking. Rather than using .120, you can go down to .090 for a bit of weight savings, without worrying about the tank not being durable enough. We build tanks up to 100 gallon out of .090, after about 80-90 gallons, then we usually start looking to maybe up the size to .100 or .120.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:http://www.surpluscenter.com/Truck-T...ER-28-1553.axdLooks like that's for a really deep tank but I remember seeing other sizes in the past.HH 187Miller Bluestar1EAHP AlphaTig 200X
Reply:Originally Posted by kkustomzBuild your aluminum tank and put a few baffles inside it. Have the 3003 or 5052 broke so you only have to weld the top and sides, there will be two pieces that fit together like a glove. Most of the tank i have done are .120 thick even a few heavy ones 3/16". Yes you can but weld in bungs already threaded or you can get a 1" solid stock 6061 and tap them yourself. Yes you can get a in exspensive sending unit that can be adjusted for your tank height, look in jegs or speedway motors for it. Let me know if you need anymore help!
Reply:Originally Posted by DSWKeep one thing in mind. Free surface liquid sloshing around in a tank can and will beat the snot out of it. That's why most larger fuel tanks contain baffles to slow down or limit sloshing. It's not so bad when the tank is full, but when 1/2 empty, especially with a tank design that allows the fuel to pick up some momentum,  fuel movement can be significant.
Reply:Here is one I did yesterday. 16.5 gallonsEfi pump and sending unit bolt in to a 3/16 5052 top and .125 5052 tank Attached Images