3003 Ally Tank T500 (Complete!)

Re: 3003 Ally Tank T500 (Finally Started)

Just watch out if your going to use fiberglass on that foam at all as the resin or most type of Bondo reacts to it and bubbles up haha
 
Re: 3003 Ally Tank T500 (Finally Started)

Hi just read this thread from the begining its full of very usefull info excellent work johnu and Roc City you have an excellent skill set and a mass of knowledge excellent.
 
Re: 3003 Ally Tank T500 (Finally Started)

Hey thanks Roc City and Johnu that was a lot of help. I've actually got some 77 spray adhesive. I thought it'd melt that foam. and that wood buck design from cutting your mold apart is ingenious. Anything to add Fab Tanks?
 
Re: 3003 Ally Tank T500 (Finally Started)

In regards to Motor's post. Duratec StyroShield over the foam.

Also, any experience with flow forming? Relatively simple.
 
Re: 3003 Ally Tank T500 (Finally Started)

Hi Longhorn I dont have anything to add I think everyone is useing the same basic ideas to build there tanks seat pans just in diffrent ways and we all have our own ideas but as long as you are happy with the result thats all that matters. I will say that if you going to have a go at your own tank buy a small shrinker strecher and always build a buck as mentioned before. Ive included a couple of photos of a seat pan on a buck for any one that isnt sure how to go about it .
 

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Re: 3003 Ally Tank T500 (need brazing help)

Agreed, nice work on the seat!
 
Re: 3003 Ally Tank T500 (need brazing help)

Help! Where do I get aluminum brazing rod? Never brazed aluminum before but I plan to braze in the bung for the petcock (Roc City's advice) and maybe the ears for locating the tank to the frame. Is brazing aluminum pretty easy, i've done a lot of brazing on mild steel so I imagine I could soon get the hang of it.
 
Re: 3003 Ally Tank T500 (need brazing help)

I find aluminium damn difficult, haven't had enough practice.
Real easy to get surface oxidation and molten 'braze' flows under it causing bulge
I gave up too easy, may try again sometime ::)
 
Re: 3003 Ally Tank T500 (need brazing help)

Here's the mkII (0.063"thk.) top mostly done. The bottom of the tank will be formed with a flange all the way around it so that basically when it is fitted to the top of the tank there will be an edge joint to weld. Should I just weld this bottom piece in then make the cutout for the tunnel and then weld in the tunnel?
 

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Re: 3003 Ally Tank T500 (need brazing help)

depends on how you're doing it... you can either turn a radius to the inside of the tank all the way around and then have a butt joint to weld, or leave the bottom as is, turn a radius on the pieces for the bottom of the tank and have a flange to weld, the flange is more difficult but technically stronger... what I'd do since its your first, is to turn the bottom of the top half so you're doing a butt weld, then use the template paper and sandpaper trick to cut out a good fitting bottom piece, weld that in and then use a handheld jigsaw to cut out where your tunnel will go
 
Re: 3003 Ally Tank T500 (need brazing help)

oh and also, before you do any of that, weld in your filler cap.

I prefer to cut the hole undersize, turn the edge to the inside of the tank, insert the cap and then weld the inside edge, much stronger and reduces the chance for distortion (big problem with a flat top tank)
 
Re: 3003 Ally Tank T500 (need brazing help)

Roc City Cafe said:
oh and also, before you do any of that, weld in your filler cap.

I prefer to cut the hole undersize, turn the edge to the inside of the tank, insert the cap and then weld the inside edge, much stronger and reduces the chance for distortion (big problem with a flat top tank)
Click to expand...

I had planned to use bolt in flush mount filler cap because I fear that, as you say with the flat top tank it would be near impossible to straighten after welding a neck in there. I will do that before welding the bottom in though, thanks for the reminder!

Do you have a recommendation for brazing rod to use for the petcock bung?
 
Re: 3003 Ally Tank T500 (need brazing help)

i used the stuff from tm technologies, i didn't like it that much and tig bungs in from now on, but if you don't have tig, it's not half bad, just make sure you focus most of the heat on the bung since the melting point of his brazing rod is like, 200' less than the melting point of the aluminum... also, careful of the threads after you weld it in, the heat anneals the shit out of the bung and the threads get really really delicate
 
Re: 3003 Ally Tank T500 (need brazing help)

I use H1-alloy flux 129 and different alloys of tig rod depending on alloy I'm using, You can get them from a local welders supply. Since you're not polishing 4043 tig rod flows nice.
 
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