Sale ends todayGet 30% off any course (excluding packages)

Ends in --- --- ---

Motorsport Fabrication Fundamentals: Step 2: Materials

Watch This Course

$99 USD

Or 8 easy payments of only $12.38 Instant access. Easy checkout. No fees. Learn more
Course Access for Life
60 day money back guarantee

Step 2: Materials


00:00 - When it comes to the material section for this project, there's not too much we need to think about as aftermarket fuel tanks are a very common part and outside of dedicated plastic fuel cells, aluminium is almost universally the material of choice.
00:14 The advantages are that aluminium is light and obviously it won't suffer from corrosion like mild steel can.
00:21 We could of course have chosen stainless steel instead but we're just going to be adding weight and expense to the part for no real obvious advantage.
00:30 The choice of aluminium does influence our construction technique though and to complete this job we obviously need to be able to weld aluminium which requires a TIG welder with AC capability.
00:41 As we discussed in the body of the course however, quality inverter based TIG welders are becoming increasingly common and the prices continue to fall so these should be a serious consideration for your motorsport fabrication tool box.
00:54 The next obvious question is what material thickness should we use for this application? Factors to consider here are the required strength and rigidity of the finished product.
01:04 On face value, there's not a lot of strength that's required however a full tank of fuel is still going to weigh around 40 kg which we need to adequately support without any undue deformation of the tank.
01:16 Experience here with other alloy fuel tanks has lead us to selecting 3 mm thick sheet which we've seen work adequately for similar applications.
01:26 The internal walls that we discussed in the previous module will also provide internal support and rigidity which will let us get away with using a thinner material than we perhaps would have if we were using a completely open design for our tank.
01:41 As for the threaded adaptor plate for the Radium surge tank, we've selected a 10 mm thickness for this.
01:46 This is sufficient to provide enough material to reliably tap and provide enough strength for the finished threads.
01:53 With our material choice confirmed, we can now move onto cutting the parts.

We usually reply within 12hrs (often sooner)

Need Help?

Need help choosing a course?

Experiencing website difficulties?

Or need to contact us for any other reason?