Composite fuel tank

Ducky

Ducky

Back in the game!
Location
Charlotte, NC
Roseand said:
Xps or eps? I have glass and resin here and a lot of the necessary consumables, so it's mostly just with stuff I have laying around. Have a cap assembly I'm using and know what fittings I'm gonna use, and I don't think they'll be too expensive. It might be a fun project, or I might not even do it all. Just a thought.

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Is your resin fuel resistant?
 
Roseand

Roseand

The Weaponizer
Site Supporter
Location
Wisconsin
Ducky said:
Is your resin fuel resistant?
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No, but if it's cheaper to use a fuel resistant coating than buy fuel resistant resin I'd do that. Otherwise I'll just buy the right resin. We'll see.. Still not sure. May have another mod in store..

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Nate_D

Nate_D

Location
Houston, TX
Roseand said:
Xps or eps? I have glass and resin here and a lot of the necessary consumables, so it's mostly just with stuff I have laying around. Have a cap assembly I'm using and know what fittings I'm gonna use, and I don't think they'll be too expensive. It might be a fun project, or I might not even do it all. Just a thought.

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Your call. Both are polystyrene and will dissolve. If you do it, make sure to document it and share. Also, make sure to do some thorough testing before slapping it in your ski. It might be a fun project, or it might be a complete waste of time. I've thought about building one, but quickly came to the conclusion that there are better materials to use for this purpose (hdpe, aluminum, etc). I think with your future in engineering, you should spend the time modeling a tank in solidworks and analyzing the cost to have them injection molded. You may never make a tank, but the experience will be far more valuable than the headache you will get from trying to build a composite tank with the materials and processes you have available to you. Just my 0.02, take it for what it's worth.

Or just forget he whole thing and go work on your backflip.


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Roseand

Roseand

The Weaponizer
Site Supporter
Location
Wisconsin
Nate_D said:
Eps
e0f2ae3ed8d5da6ca24640602d5701ee.jpg


XPS
26e6499e7d214baff2929b2a0f369134.jpg


Your call. Both are polystyrene and will dissolve. If you do it, make sure to document it and share. Also, make sure to do some thorough testing before slapping it in your ski. It might be a fun project, or it might be a complete waste of time. I've thought about building one, but quickly came to the conclusion that there are better materials to use for this purpose (hdpe, aluminum, etc). I think with your future in engineering, you should spend the time modeling a tank in solidworks and analyzing the cost to have them injection molded. You may never make a tank, but the experience will be far more valuable than the headache you will get from trying to build a composite tank with the materials and processes you have available to you. Just my 0.02, take it for what it's worth.

Or just forget he whole thing and go work on your backflip.


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This will be when the lakes are frozen ;P backflip practice is today!

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Vumad

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
Ive been wanting to build my own tank for a long time. I just dont trust the resins. Even if the tank doesnt leak, think of what is at the bottom of acetone when you clean a tool. Imagine that breaking down and running through your carbs or other components. No thank you.

I believe the best solution is a tank bladder inside of a composite shell. It would significantly reduce the mass of the composite and ensure no leaking would occur. It could also be a 2-part tank since it would just hold the shape of the bladder, so it could easily be built from a mold with an amazing finish. I have not yet found a good source for such an item. Most bladders are designed to hold their shape above deck or fill a simple void below. I would want something that could take a complexted shape. Think of the old fashion ice bags. If it cant hold a complex shape, it might as well just be aluminum or preconstructed plastic.
 
Roseand

Roseand

The Weaponizer
Site Supporter
Location
Wisconsin
Vumad said:
Ive been wanting to build my own tank for a long time. I just dont trust the resins. Even if the tank doesnt leak, think of what is at the bottom of acetone when you clean a tool. Imagine that breaking down and running through your carbs or other components. No thank you.

I believe the best solution is a tank bladder inside of a composite shell. It would significantly reduce the mass of the composite and ensure no leaking would occur. It could also be a 2-part tank since it would just hold the shape of the bladder, so it could easily be built from a mold with an amazing finish. I have not yet found a good source for such an item. Most bladders are designed to hold their shape above deck or fill a simple void below. I would want something that could take a complexted shape. Think of the old fashion ice bags. If it cant hold a complex shape, it might as well just be aluminum or preconstructed plastic.
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Yeah I was doing some research on bladders and I couldn't find anything that would work for what we want either.

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Ducky

Ducky

Back in the game!
Location
Charlotte, NC
test fit the stock superjet tank....save yourself some headaches and worry about other things then building a gas tank out of unconventional materials.
 
Vumad

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
550 tanks are not all that great. They have a larger foot print than a 3gallon has tank. They often have to be put in sideways which is inefficient for the pickups and makes the full unuseable. They are also often old and full of spider cracks.

They are a cheap alternative to a jazz tank but not good for much else.
 
BRANDO6X

BRANDO6X

Location
MI
I think it is a great idea, you can really optimize the small amount of space you have in the hull... Maybe someone could one day integrate the tank into the hull and gain some hull stiffness and strength... anyway.. I also plan on making one at the end of winter. I think the potential problems with fuel resistance and impact strength should be pretty easy to address, although I suspect the first part may be overbuilt. As for cost... not so sure it will be cheaper than an Al tank. As @Nate_D mentioned, I think this project will nickle and dime you past $200 easy... I was going to just give it a try guessing the thickness and such, but if you want to try it first, I would be happy to see your results :)

As for the fuel resistance, I think caswell tank sealer is your best option for a coating. As for a resin, I gave uscomposites a call a while back and asked about fuel resistant resins and they gave me a recommendation. But I cant remember what it was... I think it was called steelcoat or steelline,, i donno... Should just be a phone call away.

I also was thinking about using the lost foam method, but I would not use acetone to melt out the foam, I think Kerosene would be a better option as it should not damage the epoxy... but you will need to do some serious prep in there prior to using the coating.

Anyway I hope you give it a try and post your findings.
 
swapmeet

swapmeet

Brotastic
Location
Arlington TX
If you have time to burn and like to be frustrated, you should definitely do it.

I'd rather spend a grand on a TIG and use this as an excuse to learn how to weld aluminum than deal with the issues related to a composite tank. x10 on Vumad's comment concerning what might be sucked into your carbs.
 
Vumad

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
swapmeet said:
If you have time to burn and like to be frustrated, you should definitely do it.

I'd rather spend a grand on a TIG and use this as an excuse to learn how to weld aluminum than deal with the issues related to a composite tank. x10 on Vumad's comment concerning what might be sucked into your carbs.
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I think a gas tank is a terrible place to learn to weld. All butt welds too. I suppose it could be pressure tested but I'd leave the on for someone who really knows what they are doing.

My plan to to make a tank out of foam with all flat sides and sharp corners so measurements could be taken from it to cad and laser cut the pieces, then have a very experienced welder put it together.

I'm all about that budget, but I don't want to explode. I've personally never exploded, but I am sure it's not on my bucket list.
 
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