Hi,
After lots of practice I'm now getting the hang of TIG welding aluminium. During the last six months I've been learning metal spinning and TIG welding both in aluminium. Initially I wanted to make a petrol tank for the Suffolk Colt mower I fully restored only then to find the original tank bottom to have lots of pin holes found after lots of work and respraying before filling the tank with petrol.
As a fist TIG project I thought I'd change the tank shape and wanted it to have domed ends hence my interest in learning metal spinning. This first tank is finished but as I've put so much time and effort into making it and making just about all the mistakes possible I've decided to keep this tank in my workshop as a reminder of the struggles I've had and it will make a good discussion piece.
Looking at the unusual shape of the original tank I thought this is going to be a challenge because I'm new to such projects and have never tried panel beating; I only have basic tools for carrying out this kind of work but it looked like it could be fun. The original steel tank is pressed out in two halves a top and a bottom joined by a central welded flange.
Why not get rid of the flange and make the tank in aluminium so I chose 2mm thick 1050 grade aluminium with same grade 2.5mm filler rods.
Having given the project a lot of thought I decided to make the tank in three sections; a middle and two ends. Next was to make a wooden plug to clone the tank shape; I was making this up as I went along; not having correct thickness of timber I glued up two thicknesses and then cross cut to length before cutting the profile on the bandsaw then hand sanding and adding the radii.
The middle section wasn't too difficult to bend carefully to shape then it was welded. Now I hit a problem; the shape of the wooden plug made it impossible for secure gripping so a lot more thought was needed. If I made a pair of handed ends from 18mm thick plywood adding the profiles I could nip these in my engineering vice with a wooden backing?
Having made the plywood plugs I set about panel beating and really struggled as the aluminium had a mind of its own; as I hit it with a dead blow hammer it buckled elsewhere causing it to buckle; if I hit the buckle then it transferred again and so on; it took ages and with an aching arm I finally had the first end but it needed trimming so a bunus was I could run the end against my 4" belt sander fitted with a 60g belt bringing it flush with the plug; this was brilliant until I wanted to remove the ply plug without damaging the newly formed end. A simple solution was drive two coarse thread wood screws into the plug giving something to grip on; another problem sorted.
Not wanting a repeat performance I decided to cut and weld the second end which looked rather crude but forming it was much quicker so now I had the three sections for the new tank. TIG welding was easy enough and I wanted strong welds rather than pretty welds because on this tank I wanted to dress the welds flush.
A small diameter hole was drilled where the filler neck would be welded in place to prevent the tank buckling as it was sealed with weld. Today I've dressed the welds using my 2" wide belt grinder; Dremel and Bosch random orbit sander then hand sanding before finally buffing using the Graduate lathe. I've ordered the new filler neck and cap through eBay and I already have a new tap; the neck will be welded in and new tank mountings welded on to finish the job.
I'm delighted with both tanks these being my first TIG welding projects; they seem to have taken forever to make but it's been very interesting indeed and I've now acquired two more useful skills.
Each welding session I gain more confidence and experience; I'd like to thank all members once again for their generous help and guidance; this forum has been excellent so I'm now in a position where I'm no longer a novice and can give something back by way of thanks.
Kind regards, Colin.
Card template of original tank profile; what a shape to attempt to copy.
The original tank with card template.
Middle section almost ready for welding. No special tools the joint roughed out with tin snips.
The wooden plug was well worth the time to make and worked a treat.
Plenty of weld piled on; the right hand end was a right pain to form but the left hand end having had wedges cut out behaved a lot better but involved more welding; not pretty welding but this didn't matter.
Both ends formed ready for welding. All in 2mm thick aluminium.
Not a bad fit at all as I'm still learning and this is totally new to me; now I've done these two ends I have a bit of experience now for next time; the wooden plugs need careful making.
Still the filler neck; tap and mountings to add but I think with even more time and care I'd have got it bang on; making the tank in three sections paid off and I got rid of the flange.
My first petrol tank almost complete and the welds aren't too untidy.
The completed tank; I've enjoyed making these and can say to other novices you'll win if you stick at it and do lots of practice welds. I might get both tanks anodized in the near future; I'd like to anodize them myself learning how to do it but I dislike too many chemicals in the workshop.
After lots of practice I'm now getting the hang of TIG welding aluminium. During the last six months I've been learning metal spinning and TIG welding both in aluminium. Initially I wanted to make a petrol tank for the Suffolk Colt mower I fully restored only then to find the original tank bottom to have lots of pin holes found after lots of work and respraying before filling the tank with petrol.
As a fist TIG project I thought I'd change the tank shape and wanted it to have domed ends hence my interest in learning metal spinning. This first tank is finished but as I've put so much time and effort into making it and making just about all the mistakes possible I've decided to keep this tank in my workshop as a reminder of the struggles I've had and it will make a good discussion piece.
Looking at the unusual shape of the original tank I thought this is going to be a challenge because I'm new to such projects and have never tried panel beating; I only have basic tools for carrying out this kind of work but it looked like it could be fun. The original steel tank is pressed out in two halves a top and a bottom joined by a central welded flange.
Why not get rid of the flange and make the tank in aluminium so I chose 2mm thick 1050 grade aluminium with same grade 2.5mm filler rods.
Having given the project a lot of thought I decided to make the tank in three sections; a middle and two ends. Next was to make a wooden plug to clone the tank shape; I was making this up as I went along; not having correct thickness of timber I glued up two thicknesses and then cross cut to length before cutting the profile on the bandsaw then hand sanding and adding the radii.
The middle section wasn't too difficult to bend carefully to shape then it was welded. Now I hit a problem; the shape of the wooden plug made it impossible for secure gripping so a lot more thought was needed. If I made a pair of handed ends from 18mm thick plywood adding the profiles I could nip these in my engineering vice with a wooden backing?
Having made the plywood plugs I set about panel beating and really struggled as the aluminium had a mind of its own; as I hit it with a dead blow hammer it buckled elsewhere causing it to buckle; if I hit the buckle then it transferred again and so on; it took ages and with an aching arm I finally had the first end but it needed trimming so a bunus was I could run the end against my 4" belt sander fitted with a 60g belt bringing it flush with the plug; this was brilliant until I wanted to remove the ply plug without damaging the newly formed end. A simple solution was drive two coarse thread wood screws into the plug giving something to grip on; another problem sorted.
Not wanting a repeat performance I decided to cut and weld the second end which looked rather crude but forming it was much quicker so now I had the three sections for the new tank. TIG welding was easy enough and I wanted strong welds rather than pretty welds because on this tank I wanted to dress the welds flush.
A small diameter hole was drilled where the filler neck would be welded in place to prevent the tank buckling as it was sealed with weld. Today I've dressed the welds using my 2" wide belt grinder; Dremel and Bosch random orbit sander then hand sanding before finally buffing using the Graduate lathe. I've ordered the new filler neck and cap through eBay and I already have a new tap; the neck will be welded in and new tank mountings welded on to finish the job.
I'm delighted with both tanks these being my first TIG welding projects; they seem to have taken forever to make but it's been very interesting indeed and I've now acquired two more useful skills.
Each welding session I gain more confidence and experience; I'd like to thank all members once again for their generous help and guidance; this forum has been excellent so I'm now in a position where I'm no longer a novice and can give something back by way of thanks.
Kind regards, Colin.
Card template of original tank profile; what a shape to attempt to copy.
The original tank with card template.
Middle section almost ready for welding. No special tools the joint roughed out with tin snips.
The wooden plug was well worth the time to make and worked a treat.
Plenty of weld piled on; the right hand end was a right pain to form but the left hand end having had wedges cut out behaved a lot better but involved more welding; not pretty welding but this didn't matter.
Both ends formed ready for welding. All in 2mm thick aluminium.
Not a bad fit at all as I'm still learning and this is totally new to me; now I've done these two ends I have a bit of experience now for next time; the wooden plugs need careful making.
Still the filler neck; tap and mountings to add but I think with even more time and care I'd have got it bang on; making the tank in three sections paid off and I got rid of the flange.
My first petrol tank almost complete and the welds aren't too untidy.
The completed tank; I've enjoyed making these and can say to other novices you'll win if you stick at it and do lots of practice welds. I might get both tanks anodized in the near future; I'd like to anodize them myself learning how to do it but I dislike too many chemicals in the workshop.