How to weld a tank on a fuel oil truck

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I have a few questions. I tried the search for Tank welding but didn't come up with what i was looking for. I have a fuel oil truck. The tank is aluminum. It's leaking where the baffle inside meets the bottom rail. this is common for older tanks.My questions are;what safety precautions would I need to take to go in the tank and weld it. Does the entire tank need to be washed out ? i don't think the place I took it once before did that. Also what kind of fresh air setup would I need. I emptied the tank once before and left it with a fan venting all day and nearly passed out from the fumes after like 10 seconds. Is this more than I can handle safely ?second Question. why does it have to be welded from the inside ? why can you weld a tank on the outside. everytime I have had a tank repaired they always went inside and did it. Just never understoofd why.Thanks.Lincoln Ranger 8Lincoln 140c MigLincoln Tombstone(doesn't everybody have one ?)Miller 200Diesel/Heavy Equipment MechanicLead Plant Mechanic Municipal Water
Reply:dunno about question 2 but dry ice is a good way to weld on a tank that has fumes in it. dump some hunks in there and wait for it to start coming out the hole at a nice and steady pace. you can purge it with argon so i have read. i even filled one with water one time and did it. have to make sure to get it all out but worked fine for me.only thing worse than an ugly woman is an ugly weld
Reply:are u talking about a very large tank you can get inside? because i was talking about a gas tank. like for a car.only thing worse than an ugly woman is an ugly weld
Reply:You're going to have to  find a professional steam cleaning service. If the have a steamer like you can find at Northern Hydraulics that's not good enough. It's going to take some like an oilfield pipe and tank steaming truck and it's going to take most of the day.The entire tank must get hot during the steaming process. It must be checked with an explosive gas meter not only after steaming and again before entering the tank to weld. The steaming company will just provide the steam for however long you pay for. It's falls on you to make sure it's safe to weld.Tough as nails and damn near as smart
Reply:Um if your talking about a placarded fuel delivery truck I think the FMVCSA wouldn't like you repairing the tank yourself.God help you if they found out you did your own repair job on the tank itself.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by acesneights1I have a few questions. I tried the search for Tank welding but didn't come up with what i was looking for. I have a fuel oil truck. The tank is aluminum. It's leaking where the baffle inside meets the bottom rail. this is common for older tanks.My questions are;what safety precautions would I need to take to go in the tank and weld it. Does the entire tank need to be washed out ?          **yes i don't think the place I took it once before did that.            ***I'll bet u doughnuts--they did** Also what kind of fresh air setup would I need.           ****either really good flow thru air changing-monitoring the air for 02 levels, or be   on your own air. I go in on my own air, plus air change flowing. I emptied the tank once before and left it with a fan venting all day and nearly passed out from the fumes after like 10 seconds.         *********You have overlooked the fact that the argon gas you'll be using for aluminum welding will kill you--if you don't have a fume explosion first.Is this more than I can handle safely ?           *****Yes this is more than you should tackle. From your questions, this is not inyour league.second Question. why does it have to be welded from the inside ? why can you weld a tank on the outside. everytime I have had a tank repaired they always went inside and did it. Just never understoofd why.Thanks.
Reply:Take it to someone qualified, certified, and experienced to do the repair.
Reply:Thanks guys. Thought this was too much. My life is worth more than that. FYI the guy who repaired tank for me in the past swears they don't wash it out. He did cut a second hatch in it though on the other side of the baffle.Lincoln Ranger 8Lincoln 140c MigLincoln Tombstone(doesn't everybody have one ?)Miller 200Diesel/Heavy Equipment MechanicLead Plant Mechanic Municipal Water
Reply:I actually just finished welding the saddle tank for the same truck yesterday and was nervous enough about that. I washed the crap out of it and let it vent for almost two weeks. Went smoothly. Did 5psi pressure test on it. Sat over night , no leaks. The big tank too much for me to handle safely. Steam cleaning the tank isn't the problem, it's what to do with the water afterwards. That's haz mat.Lincoln Ranger 8Lincoln 140c MigLincoln Tombstone(doesn't everybody have one ?)Miller 200Diesel/Heavy Equipment MechanicLead Plant Mechanic Municipal Water
Reply:Originally Posted by acesneights1Thanks guys. Thought this was too much. My life is worth more than that. FYI the guy who repaired tank for me in the past swears they don't wash it out. He did cut a second hatch in it though on the other side of the baffle.
Reply:I personally am glad Dave brought a degree of sensibility to this thread.  Good advice based on real world experience.With that said, I still wonder why there are posters who feel it necessary to comment on issues where they obviously have no experience.Giving advice on welding fuel tanks, with no experience in the field, is downright dangerous and irresponsible.  If you don't know what you're talking about, then don't say anything.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Have a DOT certified tank welder do the job! It will save you alot of trouble in the longrun.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Believe me I am. I think the only reason I posted in the first place is to get some response and get the idea out of my head once and for all. I will watch very closely how they do it this time and report back. I am sure they don't wash the tank out because I remember looking inside last time and it was not washed. I think he vents it somehow which is why they cut the extra manhole in.Lincoln Ranger 8Lincoln 140c MigLincoln Tombstone(doesn't everybody have one ?)Miller 200Diesel/Heavy Equipment MechanicLead Plant Mechanic Municipal Water