Build Your Own Aluminum Fuel Tank

It was time to custom-weld an aluminum fuel tank for my boat. The basic concept is not very hard however ensuring top-quality welds that don't leak takes a little more know-how. Anyone with an AC TIG welding machine can pull this off with a little practice. Finding the parts can be a little tricky but they are out there.
I used www.boydwelding.com/
​ for my fuel cap. The quality of the part was excellent and they are made in America. They also can do custom fuel tanks and have generic ones available.
For more information on Adventure Marine please visit the website
adventuremarine.ca/
​
As always thanks for watching and good luck with your own build. Please leave a comment and tell me about it. Cheers, Greg
00:00 - intro
02:10 - Weld fittings
03:37 - Tank welding

[@baddboat]

I know this video is a couple years old but it's very helpful, thank you. I just bought a 2024 Sun tracker pontoon boat and it has a really crappy plastic gas tank. It swells up and pulls the gas pick up out of the gas😂 I think aluminum gas tank is the answer!

[@gregepp3082]

Yes, the vid is quite old now. My tanks have come a very long way since. Our website is here if your interested in having us build one for you. adventuremarine.ca/ Thanks for watching and commenting! Cheers. Greg

[@ls2005019227]

I've been considering building an aluminum tank for my boat for months- This video answered the questions that were holding me back! Thank you! Subscribed

[@gregepp3082]

What question was holding you back?

[@ls2005019227]

@@gregepp3082 - Mostly on venting the tank- I just got the needed aluminum last week. Will be more of a vertical/angled type of tank, & rather than a pickup tube, am planning to make a pickup fitting near the bottom.

[@gregepp3082]

@@ls2005019227 Right on Robert! If you have any other questions you can always shoot me an email or post here. Cheers and good luck with the tank.

[@jrautofabwerksllc7556]

Shout out from California new sub

[@tinybrown6710]

Is it possible to try a welding glass filter in front of the camera to see the weld more clearly, might save the sensor in the camera a bit as well. Have heard the brightness of welding killing light sensors. Also do you test your welds by pressure or vacuum draw over time?

[@gregepp3082]

Yes, I have started playing with different filters for the camera. I have heard you can burn out the lens also however that camera seems fine still. As for Pressure testing Transport Canada requires tanks to be certified to 33 CFR 183.510(a) This is also the same standard for the USCG as well. Basically a 3-4 psi positive pressure test.

[@eglicomet]

Fantastic! Did you use 6061? What thickness? I'm rebuilding an old downeast center console and plan on welding up the tank for an underfloor fuel system.

[@gregepp3082]

Good question, If you want to meet regulation for a fuel tank you will need to use something like 5052, 6061 is suitable to bungs and connections but the main tank should be 5052 (1/8" thick) or better. I'm going to do a vid on this soon.

[@icarussisyphus5201]

Nice job. Did I miss the part of the video to tell me the type of aluminum and its gauge?

[@gregepp3082]

5052 and it's 1/8" inch thick.

[@abidhajher7076]

Could you use brazing rods instead of tig welding??

[@jayyep6974]

So you vent vapors and fuel into youe boat? Good idea

[@gregepp3082]

And were does plastic kicker motor tank vent to in an open boat Jay?

[@jayyep6974]

@@gregepp3082 plastic tank in open boat vents into open atmosphere. Your tank is in an enclosed area

[@daanvolvo5719]

How thick is the plating? Didn't hear it in the video. But great video.

[@gregepp3082]

I use 1/8" thick Aluminum 5000 series. Thanks for watching!

[@HawaiiGoesFishing]

Great demo. What was the thickness of the material?

[@gregepp3082]

thanks for watching, 1/8" thick 5000 series

[@chucksgarage7165]

@@gregepp3082 1/8" seems a little on the thick side to me. Was this thickness chosen due to welding concerns (ie warping or burning thru) or is it needed for strength?

[@milesabove5259]

You didn’t explain any of the things that are specific to building a fuel tank. Keeping it clean inside as you go or do you have to wash it out after? Did you fill the tank with argon during the welding or is it not necessary? What sealant did you use for the pickup fittings. How is the sender isolated for the 2 gauge wires? Did you pressure test it after and at what pressure? Is there a formula/rule to folding the pieces? I have done a fair bit of welding but only new to tig at home. I’m sure it’s more than just making a box and putting the fittings on it?

[@gregepp3082]

Thanks for the great questions. I did not purge it with argon, I did clean the parts with acetone first, I used normal Teflon tape for the fittings, the sender comes with instructions and its own gasket, I did a pressure test after with a shop vac on reverse and a bottle of soapy water. You (can also fill the tank with water and let it sit overnight) as for folding ie forming, use a .250 die or the material will crack. Unless it's a 4000 series. I maybe did oversimplify the process... But If you need more specific help feel free to shoot me an email.

[@Eluderatnight]

If over 30" in any direction it requires a baffle per uscg.

[@scottbarnett8189]

What is the piece you installed between the filling point and the fuel pick up

[@gregepp3082]

I believe that was the breather vent I made. However, since the making of the video, I have learned it would likely not meet Transport Canada regulations for tank breathers.