Tips on making a fuel tank

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I have a 1978 F-350 that has a severely rusted gas tank. Common sense tells me to order and pay the $258.00 for an aftermarket tank and get it over with, but since I use this truck very little (less than 75 miles last year) I was wondering if anyone had some suggestions on what to use to fab up a homemade tank. I have some 10 gallon propane tanks but really don't want to take the chance of blowing myself or others up while trying to modify them. I have thought of buying a new portable air tank and using it, but don't know if this would be a safe route to go because I thought I read somewhere that fuel tanks need baffles in them to stop the sloshing. The other option I was thinking about is welding up a rectangular tank from 1/8" steel sheet. I made a hydraulic reservoir for a friend out of the 1/8" material and it turned out pretty good and leak free. I just don't like the thought of spending the money on a new tank for a truck that see's very limited use, but on the other hand I don't want to expose myself or others to a rolling fireball that does not meet D.O.T. standards in the event my truck is ever scrutinized by the State Patrol. Anybody ever attempt something like this that would be willing to share their methods and/or ideas? I would like to have at least 10 gallon capacity if this can be accomplished safely.........thanks.
Reply:Stainless beer barrels have always been a personal favorite of mine.  Half barrels are 15 gallons, and don't need baffels.I use them for generators because I don't like paying a dumass fireman $65 to watch me refuel a genset at a festival.  Oddly, none of the festival officials ever question a beer barrel hooked to a concession trailer.Appreciation Gains You Recognition-
Reply:Franz,Thanks for the idea. A local beverage company has had several of them barrels sitting in a fenced area for eons. Maybe they are leakers and just need some minor repair. If I decide to use the barrel idea I will have to check to see if they can sell or give them away, or if they are the property of a brewing company. The diameter of these barrels may pose a mounting problem because the hydraulic dump lift equipment is mounted inside the frame rails and leaves barely enough room for the stock tank which appears to be about 6 or 8 inches narrower than the barrels. Maybe I could fab up some steps, weld them to the barrel, then attach the unit under the rocker panels just like the big rigs D: ........thanks
Reply:Aluminum is fine for gasoline also.  If you look at what is filling up your local gas station, it's aluminum.  I guess the theory behind aluminum and petroleum is that if the tanker truck turned on its side, it wont burst into flames because there's little or no spark from the aluminum sliding down the road.  So an aluminum keg would do the job just fine.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Franz-Whatcha peddling at them festivals?
Reply:Shop at a couple parts stores for that tank, I pay about 125$ for one thru Auto Value or Parts Plus.  Even the Napa isnt that high.  Ford used that same tank for almost 20 yrs.  That price isnt right,, and at 125 it would be a no brainer to replace.  POarts are cheap for those, I have 2 78's in service yet, master cyl, 18$, wheel cyls 10 and tie rod ends 15.  Even drums and rotors are cheap. Find an auto parts store that deals,, mine is very competitive but I do a 1000 a month with them, but they deal well with anyone.  One item it is worth looking for and pricing is electric fuel pumps for newer trucks, there can be a big difference in price.Last edited by Sberry; 05-01-2004 at 12:51 PM.www.urkafarms.com
Reply:I peddle electrons, my buddy peddles ice cream and lemon ice to yuppie fruits and the artsyfartsy folks.I was thinkin of peddlin prostitutes, but them gals just wouldn't stand a chance competin with dumass politicians.Appreciation Gains You Recognition-
Reply:for $90, I'd just buy one from here:http://www.quantaproducts.com/store/...s.asp?dept=80?