Building a custom fuel tank by brazing?

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I probably already know the answer, but is it possible to join the seams of a custom fuel tank, made out of aluminum by brazing?Would I have to use an Oxy/Acel torch or can I use Propane? I know the easiest way would be to TIG it, but I don't have access to a TIG and my HF 90 amp is not up to the task. I'll have to check out the metal fab shops to see if they even have the ability to mess with aluminum, so I guess I'm a few hours at a minimum away from speaking to somebody face to fact with my template. I'll probably just make it out of steel and then use a coating on the inside of the tank. I'm building a "Frankenjeep" and the roll cage is impeding on the location of the stock location of under the driver's seat. The body tub is a '49 CJ-3A so a fuel cell behind the seats in the "cargo" area is also out of the question. I have two locations between the frame rails, one above the axle and the other above and behind it. Since I'm using a mid-'50's frame, it has a triangulated hitch mounting area integrated into the rear bumper. Like most things on 'ol "Frank" everything is a compromise so I'm going to be giving up total fuel capacity in order to fit it in the safest spot possible. I'll give up some on the departure angle with a robust skid plate under a tank. I have a lot of idea's floating around my head, but this is the biggest question about this conundrum so far. Thanks,OlyLast edited by TRBrew; 12-29-2014 at 11:57 PM.A Refugee from the Peoples Republic of Minnneeesootah living on the Prairie of Eastern Montana.3-7-77
Reply:Yes! you can ABSOLUTELY braze a fuel tank (I assume you are talking about aluminum).  I've only ever done that job with Oxy/Acetylene, but you could definitely use oxy/propane.  I suppose it is possible with just propane...I'd have to check.KevKevin / Machine_Punk from The Aerodrome Studio - Lincoln PowerMIG 210 MP - Meco N Midget w/custom welding station - Vintage Victor 100Current Projects: The Aerodrome Studio
Reply:Thank you!And yes, I'll fix the post to state that. So the question would be whether or not I could get away with just propane or source a oxygen/acel torch.A Refugee from the Peoples Republic of Minnneeesootah living on the Prairie of Eastern Montana.3-7-77
Reply:trb; i bet you could find lots of 411 on youtube also alcoa has a book on brazing aluminum.i.u.o.e. # 15queens, ny and sunny fla
Reply:"Propane" can mean a lot of different things, from the cheap disposable cylinders usually sold for doing home soldering of pipes, the the commercial air/propane rigs some plumbers use to Oxy propane setups.I'm sure Oxy propane would get hot enough to do the job. The others I don't know. Keep in mind alum is a great heat sink and will wick away the heat you pump into the system pretty quick. You may be able to do something with a small piece that gets heat saturated pretty quick, but may have issues with larger pieces that can pull heat away and dissipate it faster than you can put it into the system..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:Under the body is a poor place for the tanks in a rock crawler. Been there, done that, replaced the tank in my 71 twice. Under the seat(s) is best. The tool box under the passenger seat is easily expendable, for more capacity. There are people who braze, or whatever you call the stuff you use with aluminum. I think brazing aluminum requires more skill than even TIG. It doesn't have the strength a weld has. If you can't weld, cut it out, draw it, and send it off to any one of 80% of the subscribers here. I myself love a project where someone else cuts it out. Use 6061 Smooth or diamond plate, cut for good fit up, (no big gaps).
Reply:Originally Posted by docweldertrb; i bet you could find lots of 411 on youtube also alcoa has a book on brazing aluminum.
Reply:Originally Posted by Willie BUnder the body is a poor place for the tanks in a rock crawler. Been there, done that, replaced the tank in my 71 twice. Under the seat(s) is best. The tool box under the passenger seat is easily expendable, for more capacity. There are people who braze, or whatever you call the stuff you use with aluminum. I think brazing aluminum requires more skill than even TIG. It doesn't have the strength a weld has. If you can't weld, cut it out, draw it, and send it off to any one of 80% of the subscribers here. I myself love a project where someone else cuts it out. Use 6061 Smooth or diamond plate, cut for good fit up, (no big gaps).
Reply:Pete Williams posted up a video a while back that was very well done. He hasn't been online for a while here so you might be able to reach him thru youtube. http://weldingweb.com/vbb/showthread.php...for-motorcycle
Reply:TR,I'm not saying it wouldn't be possible to put together your own custom aluminum fuel tank using brazing but I think you'd be way better off using material in the 3/32 to 1/8 thick range and having it TIG welded.   I'm sure it would end up being way more durable and take a whole lot less time and effort to get it built.   Where about on the prairie of Eastern MT are you?   I'm in the Great Falls area.
Reply:Originally Posted by storemanHave searched Alcoa for the book.  No luck.  Link?
Reply:1971 was the first year of AMC owning Jeep. It was also the first year for the rear gas tank. The skid plate wasn't much to brag about! I was sixteen when I made the sales pitch to my father that if we split the cost of a 71 Jeep with 3000 miles, he could sell his 1965 for his half of the price. For him it would be a break even transaction. The 1947 he bought me when I was 13 was too slow on the highway to be a daily driver. This "new" Jeep was the ultimate! It had a Buick 225 the V6 was a shortened V8 they idled rough as there were two pauses in the sequence for each of the missing cylinders. Over the years it was out of service, then revived a few times. in 2011 my son wanted to breathe life into it again. Body off, he had beefed up the frame, done brakes, exhaust, steering, seals, etc. He was talking about the choices of steel, or fiberglass body when hurricane Irene hit. After the flood it lay in a once again dry brook bed half buried in sand. I don't think it will come back this time. We have a 99 Wrangler with inline six for everyday. They have come a long way since 1938 American Bantam prototypes.Consider a 1/4" bottom on your tank, or if you are sure about no rock crawling, 1/8" would do. If you have any doubts about the winch I'd be very interested.
Reply:Originally Posted by HT2-4956TR,I'm not saying it wouldn't be possible to put together your own custom aluminum fuel tank using brazing but I think you'd be way better off using material in the 3/32 to 1/8 thick range and having it TIG welded.   I'm sure it would end up being way more durable and take a whole lot less time and effort to get it built.   Where about on the prairie of Eastern MT are you?   I'm in the Great Falls area.
Reply:Originally Posted by Willie BConsider a 1/4" bottom on your tank, or if you are sure about no rock crawling, 1/8" would do. If you have any doubts about the winch I'd be very interested.