[Moph]

Busted my Sierra fuel tank on a trip up north last week ... cracked through a ridge between two previous dints. It's fairly nasty - about 35mm long and growing, with a fork halfway along the crack leading onto a second ridge. Can't seem to patch it well enough that it will hold so I think I'm up for a new tank.

I found when we were away that I was using my first jerry (20L) heaps but didn't touch my second jerry once. So it seems like 60L would be about the right tank size for 'touring' with a camper trailer on the back (avg 15L/100km).

Am thinking about welding my own tank up using 1.6mm mild steel plate. Is this a crazy stupid idea? I am confident I can brace and baffle it adequately, and with a few more hours playing on scrap steel my welding will be up to scratch. If its leak tested and pressure tested then I can't see it posing a real hazard. Am I an idiot for heading along this route though?

[ajsr]

I made fuel tanks for brown davis for a while about 12 years ago.
its not as easy as you might think. And you dont want to make it out of mild steel, you wan aluminium coat steel as mild will fill you fuel system with rust.
you want to be a good welder and pressure test it well before fitting otherwise your going to be chasing fuel weeps for ever.
the trick is to have as few welds as possible and fold as much as possible.

[lump_a_charcoal]

ajsr wrote:

I made fuel tanks for brown davis for a while about 12 years ago.

That is very handy to know...