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Fuel Tank Ends

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Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Mon Dec 04, 2006 3:35 pm Post subject: Fuel Tank Ends

Scratch Builders,



I am making the end caps for the fuel tanks and wanted to ask others about forming the corners.  Should I shrink the metal and have a corner all around?  Or, just form the flanges and leave the corners out and fill with weld?



I made some parts with 5mm constant flange, but had to anneal the corners to get the 6061 T6 material to flow.  The parts look OK just didn't know about fatigue in the corners. 



What do you think?



Pictures attached at the forum

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_________________
Ron Lendon
WW Corvair with Roy's Garage 5th bearing
CH 601 XLB
N601LT - Flying
http://www.mykitlog.com/rlendon
Corvair Engine Prints:
https://sites.google.com/site/corvairenginedata/

larry(at)macsmachine.com
Guest

Posted: Mon Dec 04, 2006 5:40 pm Post subject: Fuel Tank Ends

Ron,

A nice shape to work with, but I'd reverse the ends placing the flanges 

under the main skins as you've done so that the heat

you put into welding is better distributed between the cap flange and 

the edge of the main skins. 6061-T6 is not the best material

for a tank as applies to a welded construct.  5052-H32 is ideal as it's 

yield to work hardening is better for holding its shape.

You're corners will fill easily the way you've got them, but if 

reversed, a little easier.  You can put more material into the weld if 

you've got 1/8-inch of drum hanging outside the main skin edge and the 

edge won't burn away so readily as the edge weld of a typical flange- 

weld would.  Practice a lot before you ruin the first set of tanks by 

making sample welds to proof your skills or that of the guy you entrust 

to the job.  I welded the tanks with clecos and then removed the clecos 

one by one and welded them shut.  If you want to make the job of welding 

much easier, make the ends out of .040 if you haven't already as less 

than that is difficult to control heat- distortion and get consistent welds.



Best of luck,

Larry McFarland - 601HDS at www.macsmachine.com

Ron Lendon wrote:

 	  Quote: 	
		   



 Scratch Builders,



 I am making the end caps for the fuel tanks and wanted to ask others about forming the corners.  Should I shrink the metal and have a corner all around?  Or, just form the flanges and leave the corners out and fill with weld?



 I made some parts with 5mm constant flange, but had to anneal the corners to get the 6061 T6 material to flow.  The parts look OK just didn't know about fatigue in the corners. 



 What do you think?



 Pictures attached at the forum



 --------

 Ron Lendon, Clinton Township, MI

 Corvair Zodiac XL, ScrapBuilder 

 http://www.mykitlog.com/rlendon





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=79162#79162





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WClagg

Joined: 30 Jun 2006
Posts: 21

Posted: Tue Dec 05, 2006 4:22 am Post subject: Fuel Tank Ends

I agree with Ron. I tried to make tamks for my 701 just like the  drawings....... three days later, half a sheet of aluminum, a bottle  of argon and half a pound of rod later I threw it in the floor. Then I  stomped it.

 Made the next tank out of .032 and turned the flange on the tank ends in.  Made it just like Ron said and in one evening I had a tank that didn't  leak. I used 6061-T6 only because I didn't want to wait for the 5052.  

 Wayne Clagg

 CH701, left wing done, starting on right.

 do not archive  

  [quote][b]

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_________________
Wayne Clagg

Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Tue Dec 05, 2006 2:32 pm Post subject: Re: Fuel Tank Ends

Larry and Wayne,



The print shows the edges coming together like the picture below and has a notation "BEAD WELD ALL FLANGE SEAMS".  This should make it easier to fuse the materials while adding filler rod and it should also make a really strong joint.  I'm not to sure about the methods you are speaking of so I will probally make it like the print.  I am still open for suggestions.

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WClagg

Joined: 30 Jun 2006
Posts: 21

Posted: Tue Dec 05, 2006 6:31 pm Post subject: Fuel Tank Ends

Ron,

 Give it a whirl and let us know how it comes out. I sure would like to  know. I really hope you get it worked out. My problem was with the weld  cracking. I would get one spot fixed and pressure test at about 1/2" water  column and it would let go somewhere else. I tried annealing and everything I  could think of. It just appeared to me that there wasn't enough meat or weld to  take any stress at all.  Be sure and let us know how it works out.

 Wayne 

 do not archive

  

  [quote][b]

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_________________
Wayne Clagg

Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Wed Dec 06, 2006 8:31 pm Post subject: Re: Fuel Tank Ends

Wayne,



I will keep the list updated on my experiences.  Going to have the welding done by a pro at work, will take pictures and document the process.

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