Easy DIY GAS TANK Design RAMP TRUCK EP-21

On this Episode of Make It Kustom, we are building the 200 litre gas tank for the COE RAMP project.
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[@jeffpitzer8521]

What I like to do when designing a fuel tank is make a mockup out of foam core board. That way you can test fit, figure out all your bungs, fillers, senders, and baffles. You can visualize the end product to make sure you like the look of it, measure the volume, check clearances, etc. It saves material, labor and time. Foam core is light, easy to cut, and tape together. Looking forward to seeing the progress. The baby Buick tee is bitchin'!

[@jalhc54TR6]

No baffles that big of a tank is going to have a lot of surge without baffles?

[@liam3976]

Every time and I mean EVERY time I get hella jealous about the sheer amount of hair on the top of Ellios head

[@briankinnear7461]

Nice work on the tank. Guess you were a little optimistic about the size of the tank though. Look forward to seeing more. Be safe and stay well.

[@MrFunnyDad2024]

Best DiY auto show on the web..

[@user-zr2eg3bk2j]

agreed!

[@bdsmith674]

I like Fitzee too. For the minimal tools and old school tricks.

[@wirefeed3419]

It is funny how Tape Measures are just like the 10 mm socket to a mechanic. Used constantly yet never around or found when needed. The bandit Raccoon shirt idea was a good laugh to imagine.

[@tstephens128]

Nice job, I've heard others say, "we make it nice, cause we make it twice". hehe.. always great seeing your dedication, art, and learning experiences on your channel. God bless you and your family!

[@dancarter482]

When I grow up I want to be able to cut straight lines free hand with a grinder . .. .. _DAMN!_

[@deltan9ne306]

As someone that's grown up, does it daily, it's even cooler when you keep the guard on!

[@dancarter482]

@@deltan9ne306 That fully enclosed helmet Karl's using makes the guard less important and more of a hindrance.

[@wirefeed3419]

@@dancarter482 The mess that happens to hands and chest is not nice when a disc explodes at 10,000 rpm. At least Karl is wearing a full face “ Most “ times. As someone that uses angle grinders I do agree the guard is a nuisance, and why it is the first thing many guys will always remove. Another better than nothing option to consider would be to reduce the size of the guard to provide the better usability yet still maintain some of the protection wanted in the rare event a disc does come apart.

[@deltan9ne306]

@dancarter482 Nothing seen in this video would have been harder to do with a guard on. We used to pie cut the guards pretty hard, so you had a spot for your hand to rest against. That's being said that's when I was young, dumb and full of cum.

[@paulvanhouts3365]

I don’t like the trend of no guard, it’s as if fingers are cut proof. As an industrial nurse I saw a few disastrous hand injuries as well as a variety of injuries from the shattered discs. It doesn’t matter the size of disc either though the huge grinders embedded bits of discs into body parts, pretty gory stuff. Having noted that I understand the issues with guards but reducing them would be better than no guard. Having a 1/3 sized arc may be worth a test for maneuverability and safety. I dare say the designers probably went through all that to come up with the current design, maybe? On the tape bandit have an elio like face with the black eyeband, like the burger bandit, with the quote, “tape? What tape? I ain’t seen no tape!” lol.

[@donbell8187]

Have you considered putting in slosh baffles in the tank? Divide the chamber into 3rds with two panels with holes?

[@terryeustice5399]

Great welding Karl. Loved the work. Look forward to completing this project. Ready to see the Zephyr again soon. Happy that you got some help coming. Thanks for sharing. 💯👊👍

[@jeffolley2712]

Love his honesty just screwed up no excuses. Takes a better person to admit his mistakes most just brush over it .Respect for your work and teaching from Australia 👍👍

[@MakeItKustom]

Thanks, Jeff! It’s all a part of it even the screw ups. I really screwed up installing a steering box the other day. Ha ha you guys will see that too.

[@grayzbildz]

Great ep once again. I've never understood why you don't do the sender and baffles before welding the outside of the tank? Now you have all that swarf inside the tank, plus welding the baffles is so much harder with less access.

[@terrys6871]

Good morning Karl! Love this ramp truck build!👌 Looking forward to the thrash weekend!!

[@albertdehn8381]

Thanks for sharing 😀👍

[@bigsquatchsasfoot1964]

Your welding is pure artwork Karl so nice 👌 super tank build ! Hey if it was easy man they’d all be doing it but it isn’t and sometimes you gotta fettle a bit even if you’ve measured twice and wrestled a tape off of Elio 🤣

[@koolkar55]

Amazing work as usual Karl. This going to be one very cool truck. What a team. Thanks for sharing Mate. Billy J..... Queensland, Australia.

[@Paul-ik8fm]

Baffles, you need baffles mate

[@joecioe8566]

Tanks for the video, I'm baffled.

[@jeffpitzer8521]

I see what you did there Joe...

[@psiked]

My second make it kustom shirt - tape measure bandit! Another great Wednesday seeing the project come to life.

[@MakeItKustom]

Ha ha gotta get on that

[@alleyoop1234]

It would be a dream building a gas tank out of 12ga, and be able to pour the welds to it.! I have built a few, but all were fabbed out of 18ga and as such all were tack welded. Even so, I get very few pinholes. Great work as always Karl!!

[@markmckeachnie4484]

Thrashing comes from farmers getting together at each others farms and bring in the harvest and the wives cooked and brought drinks out to the field and cooked all day

[@murdoc6501]

Always amazed by your welding skills! Go Karl and Elio, keep moving forward!

[@boogiewoogiebubbleboy2877]

Umm, I have some questions, Karl, mainly because here in the UK, we do things a lot differently. You may remember me telling you i own three shops. Enginering, vehicle servicing, MOTs, and repairs plus a vehicle bodyshop. Well, we're working on a volvo 2.4 C70 Estate conversion to an open top which they said couldn't be done. We have five other projects equally challenging but right now, im in the middle of replacing the rusted out fuel tank of a 1971 Ford Capri MK1 face lift. It once held 12.75 gallons and the replacement alluminium tank now holds 13.92 gallons. In addition to that tank we are now building a pair of custom fit aluminum tanks which will each hold 11.35 gallons and will be situated within the rear quater panels to feed the monster Land Rover V8 engine we have fitted. The owner wanted to upgrade the 1600 crossbow standard engine for something more beefy he said. So, we just happen to have a fire damaged 2008 Range Rover Sport Supercharged out back with a perfectly good engine. The car has done less than 30,000 miles. Is that beefy enough for you sir, I said. The look on his face said everything, and that's what this work is all about, right Karl? Perhaps you could cover the answers in the next Ramp Truck video? 1. Why didn't you put baffling in the tank? 2. Why didn't you make all those cuts, drill holes, and grinding alterations before welding up the tank? You knew where everything was going to be located, considering the free program you used to mock up the tanks reservoir. I use a similar free open source program to build my tanks totally in-house. 3. What do you do about all that contamination from grinding disks and metal shavings, not to mention welding splatter. I'm thinking of it rolling about in the fuel fouling up the sender unit and possibly damaging the rubber lines and filters. I wouldn't be able to sleep at night thinking about it. 4. Why just the one tank? Most trucks here that haul use two tanks. It would be a great addition if your rig had two tanks, totally brilliant. You could switch from one to the other like they do on planes. That woukd be cool. Imagine people faces when they see two fuel gages on your dashboard. The questions it will raise. Oh, one more thing. I've said this before but i don't do social media for many reasons but I do subscribe to both your channels. Great work fella, great work.👍🏴󠁧󠁢󠁥󠁮󠁧󠁿⚒️

[@TheDistur]

Tape measure bandit! 🦝 Tank looks good!

[@ronbunker5778]

Looking forward to seeing all the guys working on the COE!. Cool tank!

[@lindenjohnson1515]

Good Morning from Ashern MB. You guys do such beautiful excellent work. As a 70 yr ol rodder you always make my day. This ramp cab-over is just such a great build all while in your very capable hands. Thank you so much!

[@stevesloan6775]

Half inch by half inch L … but you’re still a WINNER! 😑 Really love your work and videos. Question: Are you worried about all of the metal deposits in the fuel tank from friction cutting, drilling, etc? 🇦🇺🤜🏼🤛🏼☮️😎🍀

[@eddiesasquatch8124]

Now kan you build a seperate vehicle fuel system where you kut that quantity of the tank to half and make a divesion from the exhaust into a lower level of the tank bubbeling up in the gas and run an intake size pipe back to your throttle intake?

[@Berend-ov8of]

Zippin' it up is a special kind of fun. It's totally relaxing, just steam trainin' along. And at the end you whip up the mask, see a long clean weld and think: "damn, I'm good .". 😎 About the tank: Give it some room. It's not structural, so you don't ever want it to touch both the bed and the frame, because it's the first thing that will give way. So keep it nicely clear from the bed.

[@gordonhenagar6652]

Dang! It's going to work out though, nice fab work.

[@professorfalken4600]

Great progress

[@mattvelardes8072]

Looks good 👍

[@samperras]

Love the show guys

[@daleking8529]

Another outstanding video! Take care

[@tbranscom1]

I wish i were close enough and able to come help you out, i would gladly do it for free if i were able just to be a part of the project and hang out. Unfortunatly my back never recovered from the last hauler i built, and being trapped in Tennessee ill just have to keep watching on youtube. I haven't touched a welder or painted a car in about 5 years and the withdrawal is real

[@freeidaho-videos]

Add a half inch spacer to the gas tank crossmember.

[@donaldhalls2189]

Great job certainly should hold enough fuel, thanks for sharing, all the best to you and your loved ones

[@paulhedman7387]

I'm enjoying every bit of this. Thanks.

[@ryanholmes2248]

Am loving this playlist and COE project! My hotmess garage loves to play hide and seek to my three tapes. Share your pain.

[@johnkranz4004]

Nice work Karl

[@pascalmenager1676]

Always good job Karl

[@johnkelly5487]

Nice job on the tank, Jack, RI, USA

[@PaulKrueger-is9lj]

Keep killing it Karl

[@eddiesasquatch8124]

Kan you build a tank to withstand exhaust pressure on one side and throttle body intake vaccum on the other?

[@mrrberger]

TIP: Grinder a slot through the upper tank face+, ratchet strap the slot closed, Tig fuse shut. Reduces tank width by 1 slot width, maybe your case needs a 9" grinder with a 1/8" slot disc. For the end gathers I drill a hole preclamp. Been there and done that on lots of applications, from tanks, to gates and panels to pipe angles, when the boss is pizz'd with Joe's stuffups and you roll out the slot and weld, you be da man. Guess you've made your mods by now so for next time.

[@williamherring5441]

Tanks!

[@peterkarlsson5416]

Now we talking. Nice job . 😁👍

[@dirtydwa]

Just one time i wish i could weld as good as you

[@keithk2926]

Karl your the master of the mig 👍be such to add foam

[@stephennovotny6157]

THAT WILL BE GRAT

[@peterblansjaar1327]

Love the Aussie number plate at 11:30... so used to seeing North American ones on walls over here

[@syedalthafahmed2248]

awwsome work doing bro

[@richardsargent113]

I've used micro locks in lieu of emergency brakes. They work phenomenally.

[@bdsmith674]

Good God man cover your skin when you're welding. The UV burns will cook your tats right off of you. Also get yourself a few cans of "dye / penetrate" for testing your welds. They are easy, cheap, and reliable. Cheers

[@budlesage3358]

you beat me to it...T-shirt OK for a few tacks, maybe, but not for welding something as large as that tank !! Skin cancer is no joke!! I was happy though that you're wearing gloves!!

[@poolmotorrepairguyFL]

I have a 400 my trunk . are awesome

[@stephengent9974]

Always test fit before welding it up. I also question your baffle design. I would have thought you would install them before welding the outer seams.

[@normanshepard5914]

Loosen the cross member that is under the tank and it will give you the room to slide it into place

[@derekcraig3617]

didn't see a vacuum go into that tank at all? gonna be possibly putting fuel filters to work getting metal out of the tank for a bit?

[@vanstechcorral]

Vacuumed the best I could on my stainless tank, but bits still showed up later in the external filter before the external pump and bypass regulator.

[@speeedskater]

tact weld a straight edge for the cutoff wheel,

[@JimIrelandIrishJr]

What about baffles inside the tank. I also suggest using sloshing compound inside to keep the surface rust free.

[@dennisschickling2249]

Nice Video. #STAYSAFE #PHILLYPHILLY 🇺🇸

[@Studebomber]

It's probably too late, but why not space the cross member down to create the space you needed to make it fit? Great video! Something a guy can do in their own shop versus paying big bucks for a custom tank!

[@Dr.CandanEsin]

The metal for the gas tank was 12G cold-rolled steel. It is prone to burn through. You selected 17V. Can you remember the wire speed? Because you traveled rather slow,, but the final weld was very demonstrative and didn't burn through. Thank you.

[@somebodyelse836]

Always bend your tanks into a rectangle and weld the seam. Recess the ends and weld.

[@MakeItKustom]

Yeah, I’ve done tanks like this before and sheet metal

[@somebodyelse836]

@@MakeItKustom when you step up to a pulse mig you'll never go back

[@tomtruesdale6901]

You can't call it custom if you don't have to "cuss tem". Great job on the fuel tank.

[@007cyklone]

Hahahahaha... just like lighters.. nice work

[@shanevonharten3100]

Talk about making it hard for yourselves. Weld all the internal structure before welding the tank together

[@marca5883]

Awesome work💚🇬🇧🌱 shame it didn't quite go in the hole...

[@MakeItKustom]

Lol it ended up going in just fine how I wanted it to. I just needed help. The damn thing is so heavy.

[@SauronsEye]

I've seen a race car from many many years ago that used steel wool in the whole tank instead of baffles. I was told it's also a fire safety measure. This was before fuel pumps were being put in the tank, if that is relevant.

[@MakeItKustom]

That’s a cool idea

[@danielvick7875]

Too funny I find myself Squirrelling tapes and can't remember where and I find 3-4 of them together? And then ! Wash, rinse, repeat!

[@jasontaylor7837]

See if you can fit a foam cell to the sump to hold fuel

[@darwinfoster7420]

Remember you want to have the sump on rear of tank not on front where I have seen many put .

[@larryreece1403]

Make the shirt! I'll buy it!

[@MakeItKustom]

Ha ha I’ll get on it

[@scottcobb4966]

👍

[@TFE_LLC]

I'm surprised he didn't try to feed the tank in from the forward side of the truck so the smaller side of the wedge of the tank was going in first. It looks like it would have fit if he did that... but probably not.

[@launceherron]

Would the tank clear if you unbolt the bed, lift it up slid it in, and then bolt the bed back on

[@willschluneger709]

More Ellio! Karl has so much talent and knowledge it’s easy to undervalue Ellio’s contributions, but seeing/hearing him more often really emphasizes how talented and knowledgeable he is.

[@dancarter482]

Apart from the tape-measure hoarding!

[@MakeItKustom]

He’s a bad ass! Does incredible work!

[@stephaniewilley2224]

A silly question from an old lady in Michigan, ... why didn't you install the baffle(s) and other internal structures BEFORE welding the tank closed ? Silly question I know but I'm just curious. BTW I LOVE to see the work you do.

[@MakeItKustom]

That probably would’ve been a better way to do it. Ha ha we were just rushing.

[@user-uq5mt8qi2p]

Like 4000💪

[@scottrickard7202]

Can u show pictures of the guys ls powered coe

[@NZMOPAR]

that's a big tank to have no full size baffles Karl it should have at lest 2 with half rounds around the edge and 3 or 4 bigger holes in the middle say 2 1/2 inch round and a bead rolled into it

[@Iowa599]

Maybe could fill with foam, to replace the (omitted) baffles. That will only occupy ~3% of the volume.

[@MakeItKustom]

You don’t think the baffles we put in is going to help enough?

[@Iowa599]

@@MakeItKustom I didn't see you put in any baffles, but I don't think you need any. It's not a race car! I just saw a comment suggesting baffles that would require disassembly, which would be pointless & wasteful since there are ways that don't require disassembly.

[@rickyfulks889]

Cant ya lower the crossmember for clearance?

[@bonesbyne9078]

Doesn't the bed frame unbolt , loosen it off and raise it try the tank in there then put the bed frame back down

[@lesgaal4017]

Baffels,Baffels , Baffels Carl .Australia

[@MakeItKustom]

Were you watching? We put baffles in it.

[@richardsmith-qy6vl]

Hey karl i was trying to find out if you use the same 75/25 mix gas for both the mig and tig on that arccaptin 200?

[@kennethstaszak9990]

With some relatively rare exceptions when helium is added, TIG is straight argon.

[@redhawk258]

Dude Elio, you're killin it dude!

[@lannyyoung9701]

no baffles in the tank?

[@MH-rb7lp]

Should have used a floatless sending unit, much better.

[@MarkSpitzer-zi8mr]

Hey im just wondering if youre worried about any corrosion issues with that tank since its mild steel instead of stainless or aluminum

[@MakeItKustom]

I’m not worried about corrosion issues I would say 98% of gas tanks are Steel and they’re made out of very thin sheet

[@larrylilly2552]

Coming along, don’t run into those bed rails when you’re moving around , ouch

[@tonyvalentini1726]

Hm where are the baffles

[@abpsd73]

Can't you just unbolt the crossmember to slip the tank in, then re-install?

[@donatoj.caputo4112]

Measure twice, cut once ...

[@Binalle]

Looks like your squeezing the large end of the tank through the small side of the bed...

[@SauronsEye]

0:03 ...and pause...you can fine tune frame by frame using the period (.) and comma (,) keys on your key board. Now, you've done that. Tell me he doesn't have some Asian in his back ground. The audio may sound like he's saying, "custom", but he's really saying the Chinese, "wei". A way to say hello, depending on the situation. Cartoonify his face onto a T shirt with a speech bubble, "WEI!" but in Chinese characters. It would be hilarious and you might make some Chinese friends just walking down the street.

[@MakeItKustom]

Lol I’m half Japanese

[@stephenranti173]

Don't They make foam baffling that would help keep sump full of gas and prevent fuel slosh.

[@bozoschoonover9051]

Half way expected Diamond plate aluminum for the fuel tank…

[@vanstechcorral]

First iteration engineered always shows a few wrinkles, even at General Motors.

[@andrekocsis2215]

OOOPS! lol