Welding gas tank

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I've got a 23 gallon tank for my '71 Bronco that I'd like to modify, but have read enough horror stories that I'm concerned about taking that job on at home.  The plan is to cut out one side and replace it with a panel that will give more clearance for my rear axle, and to add a bung for EFI return.  I'm a competent amateur, and have the gear to purge with straight argon while cutting and MIG welding.  It's also been sitting empty for a year and a half.  Is this as terrible an idea as I suspect, or can it be done safely?  I'd rather not spend $600 for a new tank, but that's cheaper than a trip to the burn unit.
Reply:NO NO NO NO NO NO NO NO NODo not attempt if it had gas in it NO MATTER how long it sat empty.I saw a whole factory burn to the ground when the guys inside attempted to cut open a tank for a VW that sat in a field for years..Cleaned it..Filled it with water and soap...No matter.... BOOM!My cousin had 3rd degree burns all over him and the other guy just about died and was in the hospital for months..You can't pay me enough to do anything with a used tank....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Zap: I am sure you've done more welding than I have. I have welded small engine gas tanks without any incident. I purged with argon and tig welded. Mort: I don't know what to tell you...
Reply:Originally Posted by zapsterNO NO NO NO NO NO NO NO NODo not attempt if it had gas in it NO MATTER how long it sat empty.I saw a whole factory burn to the ground when the guys inside attempted to cut open a tank for a VW that sat in a field for years..Cleaned it..Filled it with water and soap...No matter.... BOOM!My cousin had 3rd degree burns all over him and the other guy just about died and was in the hospital for months..You can't pay me enough to do anything with a used tank....zap!
Reply:Originally Posted by That Guy ThereZap: I am sure you've done more welding than I have. I have welded small engine gas tanks without any incident. I purged with argon and tig welded. Mort: I don't know what to tell you...
Reply:Originally Posted by zapsterWhen you see these things for real up close...It stays with you for LIFE.Many have tried to get me to cut this weld that on GAS tanks and they are shown the door..I have done DIESEL and OIL tanks but gas tanks I will not touch.I even modified the fuel tank on Marc's dragster but that held Methanol...Call me scared or whatever you wish but this is a very touchy subject for me and in my estimation it's just not worth it.Not to me anyway....zap!
Reply:After 35+ years of dealing with heavy equipment and trucks, I feel diesel and oil tanks are just as dangerous as gas tanks. Its much harder to remove all oily residue from seams and such. The only way I ever would touch one was to steam them for hours, then fill them with water as high as possible, then add several pounds off dry ice to generate CO2 in the air space. That still made me nervous.
Reply:Why take chances? Build a new one, they actually go together pretty fast.  If you have a break, or have someone with a break, bend two sides, and make two long welds, and the ends. See, already done! Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Build a new one. I refuse to work on used gas tanks after a few near misses personally and all the horror stories. I recently turned my older brother away, I refused to do it and it was a tiny pin hole on a  beautiful custom Harley tank I made him a few years. He was pissed at me for weeks as he just didn't understand. I never did it and he paid someone else. I had one blow up in my face and it took me a half hour to find it afterwards. Soon as I hit the pedal BAM! And it was gone!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermikeBuild a new one. I refuse to work on used gas tanks after a few near misses personally and all the horror stories. I recently turned my older brother away, I refused to do it and it was a tiny pin hole on a  beautiful custom Harley tank I made him a few years. He was pissed at me for weeks as he just didn't understand. I never did it and he paid someone else. I had one blow up in my face and it took me a half hour to find it afterwards. Soon as I hit the pedal BAM! And it was gone!
Reply:Thanks, guys.  I figured that was the answer, but wanted to double check. Any good resources on building tanks? That's a project im game for.
Reply:I agree completely!!! Don't modify that tank if at all possible! Sitting empty will actually make the situation worse.... I repeat WORSE....  When tanks sit empty they rust no matter what, all the fumes and leftover patrolium will get trapped under the rust film and wait for years to explode the second you hit a rust bubble with an ignition source.The only way I have ever welded old fuel tanks was with a meuratic acid bath first then double rince and purgeing for an extended period..... I still DO NOT recommend Welding fuel tanks because it's never ever ever a 100% sure thing.Please be safe no matter what route you take! We don't need another story, there's already too many!Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:What better way to get some time behind the hood.  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:Originally Posted by CEPWhy take chances? Build a new one, they actually go together pretty fast.  If you have a break, or have someone with a break, bend two sides, and make two long welds, and the ends. See, already done!
Reply:Originally Posted by Welder DaveBrake.
Reply:I thought you loved sheet metal...
Reply:Anything thinner than 3/8” makes me nervous! Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:You sure that tank is worth $600 new? If you don't want to build from scratch as noted above, check the aftermarket suppliers. I got one up here for a Chevy pickup for around $130 and Cdn. prices are usually higher.Edit.... ok, I take that back...cheapest 23 gallon metal one I googled with EFI was $459. You could always go poly if you aren't an offroader. http://raybuck.com/c-203060-gas-tank...ene-tanks.htmlLast edited by whtbaron; 01-01-2015 at 04:04 PM.250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:Originally Posted by CEPAnything thinner than 3/8” makes me nervous!
Reply:Originally Posted by docwelderyou mean 3/8" isn't sheet metal??
Reply:Anybody help me troubleshooting a old mm 200.  I lost power just sparks a little when I try welding.
Reply:Anybody help me troubleshooting a old mm 200.  I lost arc.Only small spark whenever I try welding.
Reply:Originally Posted by jyexleyAnybody help me troubleshooting a old mm 200.  I lost power just sparks a little when I try welding.
Reply:Sorry about your stuttering problem that must be a hassle. Lmao I'm such a jerk. I had that problem once but I brought the machine back, it was still under warranty. It was a miller mm185. All they told me was the points looked like they were 20yrs old. I know theres contact points in the gun assembly, but that is for your feed, and it was feeding fine, just a little spark and then nothing. 7A749 is your guy here. Hope he chimes in for you for you for you for you. Sorry still laughing and need sleep.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I burn them out. Flush with copious amounts of water. With lots of bare gravel around set it with filler up. Rip a 1" wide strip of old sheet three feet long. drape one end in the filler neck, from 2' away light it, get back. When the vapors ignite there's a huff, it might burn lazily for an hour or more.Thanks bud
Reply:If your that worried about them going boom, just have a radiator shop boil it out for a few bucks, that also takes all the crude out of them, then after welding reseal the inside with one of the gas tank seal kits, most of the time the pin holes will be filled with the reseal kit and no welding needed...Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...