Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 10:25 am
by BobDz
Just curious if anyone has attempted to use an aluminum fuel tank?
It appears to me to be relatively easy to make. Either a welded assembly, or a riveted assembly with a tank sealer.
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 10:44 am
by Bryan Cotton
I know one was made down in Area 51. The cool thing was that it was lighter. I’d consider it if I built another. I’ve had no issues with my poly tank.
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 10:51 am
by BobDz
Bryan Cotton wrote:I know one was made down in Area 51. The cool thing was that it was lighter. I’d consider it if I built another. I’ve had no issues with my poly tank.
Lighter was my motivation.
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 11:20 am
by Area 51%
The one I made was 3lbs lighter than the plastic job. It also holds another 3 gallons because I made it to fit under the glare shield better than the stock tank.
Never had a fitting pull loose either.
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 11:26 am
by BobDz
Area 51% wrote:The one I made was 3lbs lighter than the plastic job. It also holds another 3 gallons because I made it to fit under the glare shield better than the stock tank.
Never had a fitting pull loose either.
Excellent! Thank you for the info.
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 4:17 pm
by kmacht
Just make sure you think through unintended consequences. An aluminum tank sitting right over your legs may not be the best idea in a crash. The plastic rotomolded tank is much more durable
Keith
#554
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 6:26 pm
by Jgibson
kmacht wrote:Just make sure you think through unintended consequences. An aluminum tank sitting right over your legs may not be the best idea in a crash. The plastic rotomolded tank is much more durable
Keith
#554
You mean like the Ercoupe, or Luscombe with the aft fuse tank, or the many bi-planes build and designed with fuel tanks there? Any durability issues the rotomolded tank may have are negated by the possibility of a fitting being easier ripped out of those plastic threads.
Fuse tanks have been around since the beginning of flight. Is it the BEST place to put it, probably not but certainly not something that would prevent me from using an aluminum tank. Once it’s installed, forget about it as far as leaks go as opposed to the ‘plastic’ stock one that seems to constantly be plagued with leaking thread issues, stress issues from turning a valve on and off. And because of the location of the Sonex tank, the LAST thing anyone wants to do it remove a leaking tank. If the aluminum tank and bungs are welded correctly, and the mounting is done properly, install it and forget it.
And the Sonex can certainly use any additional fuel capacity obtainable.
Nice job on that welded tank!
Joe
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 8:54 pm
by BobDz
There are plenty of examples of welded aluminum tanks.
And…
There are a few examples of riveted tanks with various forms of sealer. Afterall, Vans wing tanks aren’t welded. And there are many suppliers of various tank fittings. I think I’m going to do it. Maybe 025 or 032, closed head countersunk rivets, and tank sealer.
Should be fun!
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 9:19 pm
by kmacht
It’s experimental aircraft so it’s up to you to choose. I just want to point out that the other planes mentioned that have aluminum fusealage tanks also don’t have a better and safer option like the sonex does. .
Re: Aluminum Fuel Tank
Posted: Sun Jan 14, 2024 9:33 pm
by BobDz
kmacht wrote:It’s experimental aircraft so it’s up to you to choose. I just want to point out that the other planes mentioned that have aluminum fusealage tanks also don’t have a better and safer option like the sonex does. .
Understood. But “better and safer” are subjective terms.
I’m not a fan of rotational poly tanks. We used two in our van build, and have replaced both. One of them will probably be replaced again. The weak link in the chain are the threads. Probably explains the use of oops fittings.
Re: Aluminum Fuel Tank
Posted: Mon Jan 15, 2024 11:25 am
by Onex107
Just for the record. There were no plastic threads in my Onex tank. The threads were in aluminum, molded in fittings, that were two different sizes. The leaks occurred around the molded in fittings when the valve or fuel line fittings were over torqued, I did not need the OOPs fittings I bought, just in case, for the eight years I flew it.
Re: Aluminum Fuel Tank
Posted: Mon Jan 15, 2024 12:33 pm
by BobDz
Onex107 wrote:Just for the record. There were no plastic threads in my Onex tank
My mistake. I misread/ misinterpreted an earlier unrelated post. Will attempt to remove my foot from my mouth.
(STILL may fabricate an aluminum tank)
Re: Aluminum Fuel Tank
Posted: Tue Apr 16, 2024 11:22 pm
by SnakePilot
Anyone willing to share plans or patterns for an aluminum B model tank?
Re: Aluminum Fuel Tank
Posted: Tue Apr 16, 2024 11:25 pm
by SnakePilot
… and a parts/fittings/hardware list and sources would be very helpful! Thanks!
Re: Aluminum Fuel Tank
Posted: Wed Apr 17, 2024 7:55 am
by BobDz
I think the parts needed will depend on whether it’s a riveted or welded tank. Besides the aluminum, you need a filler, vent, and fuel outlet to the engine. The race car, and boating world’s have a multitude of weldable aluminum fittings for a welded fuel tank.
I did find one, only one, professor YouTube video on a riveted tank using much lighter aluminum sheet. I found a tank filler that is a bolt on piece, which can be riveted, on Amazon.
Re: Aluminum Fuel Tank
Posted: Wed Apr 17, 2024 10:22 am
by SnakePilot
@BobDz, thanks for your reply.
Were you able to acquire patterns for the tank, or are you going to create your own?
Re: Aluminum Fuel Tank
Posted: Wed Apr 17, 2024 10:40 am
by BobDz
SnakePilot
I will most likely create my own. Should be easy enough. I do have the poly tank in my shop that I could use as a template. I figure I can start there and make any modifications or adjustments as needed. I’d like to come up with a better fuel fill situation, but I need to be farther along in my build to easily visualize that. Probably need to be farther along in my decisions as well. I was all set to go with an AeroVee Turbo, but after my recent issues with backorders, that’s probably not going to happen.
If you didn’t live so far away, I’d just come over and help build the tank. Two heads, etc…
Re: Aluminum Fuel Tank
Posted: Wed Apr 17, 2024 12:03 pm
by SnakePilot
OK, thanks. Please stay in touch with your project and your discoveries.