VonYinzer said:All the info ya need is out here in DTT land. Take your time, use the right materials and tools, build proper molds, and expect to spend more time and cash than you planned. Stop yelling at me, and good luck. Make sure to take lots of pics, I for one am really interested in how this all turns out!
Okay I've been lurking on this thread for a while, good stuff but could use some more info...so here goes
1. Do not use the white beaded Styrofoam unless you really like a mess..it also does not shape easily.
Use the blue or pink expanded polystyrene insulation.
2. When building your buck, cut the sheets of insulation to the approx. height and length, then glue together with insulation adhesive or silicone sealant...just a 1 inch strip down the center will do...you just need it to hold together on it's own. At this point you should have a large block that roughly resembles your tanks OUTLINE.
3. Now you start carving...I've used everything from electric knives to hot wires, rasps, Surform tm tools, 40 grit...use your imagination...it's your tank!
4. You can use Bondo tm, but i use whats known in the aviation industry as "dry micro"...a mixture of epoxy and microballons or microspheres...its more expensive but a lot easier to sand.
5. Once your buck is sanded to shape, seal it with a coat of primer or more if needed, then paint with a gloss color...I prefer enamel.
6. NOW you can wax and lay up the fiberglass.
I don't know about auto fuel, but avgas has NO alcohol in it, so I've always used epoxy. You may need to use polyester or polyvinyl resin to make the tank fuelproof to auto fuel.
Here's some links to good suppliers
www.smooth-on.com casting supplies and moldmaking
www.aircraftspruce.com resins, glass, foam and some really cool fuelcaps
www.fiberglast.com resins, glass, and other materials and tools
Have at it!
