Welding a gas tank

I want to get my gas tank modified to a through-the-hood filler by moving the filler tube to the center of the tank. The local welder says once the tank is used you cannot get the gas residue out of it no matter how many times you wash it so it's a dangerous job. He gave me the impression some welders will do the job and have the skill/tools to do it. I'm trying to avoid buying a new tank. Any of you welders out there know what's involved?

Bruce! Welding a gas tank? Piece of cake! Navy's been doing this around here for years on both gasoline and diesel tanks, and so do some of your local propane tank refurbishers down your way.

The trick is to wash the tank out well, and then use a steam cleaner to fill the tank full of steam while welding it. The steam displaces the air in the tank that would otherwise feed the flame. Theoretically (I love that word) you could use one of those "Steam Shark" cleaners with the long wand put inside the tank and run it for a while to really fill it, but if I was welding it I would want a LOT of steam in there.

Around heah in Roe Dyelin, we can take our tanks to sum adah rad'iatah guys who steam and weld'em. No sweat! 'Sides - it's about da same as a rad'iatah tank, right? Had my tank filler neck moved to da udda sideuddatank at a rad'iatah shop an' it's mint.

Oops! Had my Rhode Islandese Translator turned off for a minute, there.....sorry! Find a radiator guy who welds gas tanks and you'll be all set.

Hope this helps.......

Gordon
the Speedstah guy from Roe Dyelin

And to think that as I was growing up, people thought I was out of place because I didn't have a New England/Massachusetts/Boston/etc. accent like most of my friends. I attributed it to the fact that neither of my parents spoke with one.

Riiiiight...

Get a good soap concentrate - simply green works well. Add soap and warm water. Not Hot not cold ...warm. Let it sit for a while say a couple of hours to allow the soap to break down the hydrocarbons. Drain it . Flush it with cold water a few times. And you should be set. Always take a sniff first to see if can pick any residual fuel vapors. Just to be safe. If you are really cautious you can fill the tank up with water and eliminate any vapor space. If your are going to go through all this trouble I would suggest sealing the inside of the tank with a sealer after your weld modification. These tanks are known for holing through.
Good Ruck

I've heard this method, but never tried it:

Wash inside of tank well.
Slipping a piece of dry-ice into the tank (it's cheap and available in almost every city) with a little water.
Put on the tank cap and wait a few minutes, until bubbling sound slows.
The tank will now be happily be filled with inert CO2.

I once saw an inground gas station tank removed, the first thing they did was dump a lot of dry-ice into it. Then they pulled it up.
-=theron

Both the Nov 2003 and Jan 2004 issues of Hot VW's magazine have articles about working on gas tanks. Nov 2003 issue talks about modifying the tank for hi fuel flow. This article talks about the dry ice method that Theron mentioned earlier in this thread. It also talks about sending the gas tank to a radiator shop to clean it inside and out.

The Jan 2004 article shows two methods of restoring a gas tank. One method involves sending the tank to a powdercoater where they can dip it similiar to the radiator shop. The other method requires sending it to the raditator shop and then painting and sealing the tank. Both methods required about $100. Seems i've seen adds for new tanks in the $35-$60 dollar range. For the amount of time and effort it might be cheaper to get a new tank and have that one welded up the way you want it.

I got it....go over to Chris Nichols house and weld next to that Eclipse"icle" in his garage. Bonus you weld the tank and help a friend.

I'm going against the grain 100% on this one....

This is a life threating idea .....A true professional welder won't touch that project ... Just walk into a welding shop and ask to have a used gas tank welded ..they'll throw you out for sure. Gas impregnates the metal of the tank and is impossible to fully remove it. Yes the dry ice method has been done but that is a show topic for a future "Myths Show"
I saw one go up some years ago and split open before it landed. Another fellow tried the same feat and burned hois Sunoco station to the ground he endeded up with severe arm chest hands and facial burns . Yes it had a good steam cleaning etc etc ...Not a pretty sight and not worth the risk of injury or worse. Best to buy a new one....unless you have updated your Personal Lines policy.

I know this is a dangerous job but there are welders out there that can do it safely. I used to work at a Chevron refinery. There are guys out there welding on pipes and tanks that have had gas and oil in them and they are welding on them every day. I have done a fair amount of welding and I would not do this kind of job myself, because I have not had the safety training to do it. But I know you can find a professional welder that could do it. But again for the cost and expense it might be cheaper to get a new one and start from there.

Now that I think of it... the refinery that I worked at did blow up a couple of times while I worked there!

I have worked for a refinery for over 16 years. The pre cautions taken were continuous gas monitoring in areas of high LEL via explosive atmopheres. Vapors are very dangerous . If cleaned properly there will be no problem . Even experienced welders will short cut the cleaning process to save a little time. End results can be fatal. In confine spaces where hydrocarbons were present our cleaning procedure included high temp steamout , citrus chemical wash followed by a cold water wash. If you don't feel comfortable welding it have it done somewhere else.
Favorite pet peeve- Seeing someone pump gas with a lit cigarette in their hand.

And I have a friend that smokes cigars while spraying a paint job on a car.....I asked that he approve of me taking out a life policy on him figuring it would have a great,non taxable return on the investment!

I think Bill had a life insurance policy when he and Monica shared a cigar once.

That's a good one !

Thanks for the comments everyone. Looks like the safest and possibly least expensive route is to purchase a new tank and start over. Now to find the least expensive and closest seller. Any suggestions?

I've been making a little progress on putting my car together. The car came with an engine, a new 1600 long block from GEM. But it was missing the all the tin, the carbs, the distributor, heater boxes, etc. I have all the tin on now and am waiting on dual webers to come via the post. I mounted all the door and hood hinges today and spent some time getting the fit just right.

But all this talk about gas tanks caused me to take a look at mine. There was a lot of rust on the bottom of the tank so I took a wire brush to it. Guess what! I wire brushed right through the bottom of it. Now I need a gas tank too! I checked some of the prices. So-Cal has them for $37, Pacific has them for $45, Kustom 1 has them for $40.

In past experiences I've learned not to fool with a used tank of any kind....rust 'n dirt will surely in up in a carb time and time again no matter what type of fuel filter you have ........Go with a new tank and a decent filter.......I run two , one larger in line "Chrysler can" type available at any auto parts store and then the usual replaceable in line filter.........Alan M

I would sugest sealing a new tank. Most of the new stamped steel tanks are made with lower grade steel . Sealing it will extend the life and increase reliabilty .A good safety measure.

Tony,

You might look at a 13 gal tank or maybe a 16 gal if you are going to buy a new one. Makes touring a little less harrowing. Thats what I did and sure am glad I did.

Bruce

I was wondering if a a 16 gallon tank would fit under the hood. Sealing and extra filters sound like great ideas. I ordered some Por 15 to treat and coat the pan and I noticed that they have a tank sealer as well.

There are four different gas tanks listed in the Real Source catalog: 61-67 and 68-74 (although I am not sure why they don't list a 1976 which is what I thought I had!). I need to buy a new tank and am wondering - what's the difference between the two?

Correction: I meant there are "two" talnks listed in the Real Source catalog for the Beetle.

Bruce,
The 61-67 had the filler in the trunk, the 68-74 connected to a gas door on the passenger side quarter panel just behind the fender. Since you were planning on modifying the tank for a thru the hood filler it probably does matter which one you get, unless you need the filler neck from the new tank to help create the thru the hood look you are after.
Tony

I meant it probably does 'not' matter which one you get.

Guys,
Be aware that some if not most of the aftermarket tanks are only 8 gallons.
I bought a replacement tank for a '64 -67 beetle from Calfornia Import parts (www.cip1.com). I expected it to be a 10.5 gal. tank. It wasn't it was the same as what's already in the car from Vintage Speedsters, an 8 gallon tank. For what it cost from CIP1 for the "box charge" and shipping, it wasn't worth sending back.
If anyone is interested, You pay shipping, and it's yours for $30.00.

Anyway, I have one ordered from CBperformanc.They say it's 10.5 gallon. I haven't gotten it yet, but CBperformance has always been a reliable source, so you might check there. I've bought lots of stuff from them (back to when it was Clauds Buggies)and NEVER had any problems.

Greg B
PS
As I recall, the weld shop next to where I used to work when I lived in California, welded filler necks on VW and other gas tanks all the time. They just filled the tank up to the neck with water. ????

CB Performance price looks good at $46.95. What kind of shipping charges are they quoting you?

Bruce
I can get you a new tank thru my supplier....Alan

Bruce,
I ordered the tank along with some other (heavy) stuff like disk brakes, so I'm not sure of exact shipping charges for the tank from CB performance.
I don't mind paying shipping for mail order, you pay for it in one way or another.
I think CBperformance only charges the actual shipping fees.

Greg B