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Post Info TOPIC: Reproduction Aluminum Fuel Tanks
Steve in Ohio

Date:
Reproduction Aluminum Fuel Tanks


This post is a slightly modified version of one that I originally made to Dean's Fuel Sender(s)? inquiry a few days ago. 

Good day again to everyone.  In the way of a very brief introduction, I'm the guy who is having the aluminum repro tanks fabricated for Dean.  I'm acquainted with him through the Lotus Europa Yahoo Newsgroup, of which I have been a member since 1999.  To date, I have reproduced close to 100 tanks since 2007. 

Anyway, I saw a Peerless GT a couple of years ago at a British car show here in Ohio, and then Dean inquired earlier this year about doing a pair of custom tanks for his restoration.  Since the fabricator just finished up a run of S2 Europa tanks, the shop has time to do a few prototypes.  Here's what I can tell everyone so far.

The fabricator is working directly from Dean's OEM RH tank, and will produce one RH and one LH tank for him - a mirror image pair.  Since the tanks are a tight fit in the under sill compartments, each panel will be slightly undersize rather than oversize - by roughly 1/16" to 1/8".  At this writing, plans are also to duplicate the OEM sending unit hole re:  its diameter, hole pattern, thread size and pattern for the mounting screws, and location. 

The two OEM fittings - for the pick-up tube and drain - will retain their OEM locations on the rear end plate of each tank.  However, NPT female weld bungs will be substituted in place of the actual fittings which are not readily available in aluminum.  I did this with all the Europa tanks.  It holds down the cost and allows each owner to use an adapter to connect to whichever size and type lines found in each car.  Everything from simple hose barbs to fitting for AN type fuel hoses or hard lines. 

Since Dean's tanks have not yet been produced, I can only estimate shipping to the UK at somewhere around $60.00 each, depending on overall weight and the cost of the shipping boxes.  No pre-production estimate of the tank price right now, but I hope to have a target price later this week.  I will post this information for everyone as soon as it is available.  Stay tuned ....

Regards,

Steve in Ohio



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Steve in Ohio

Date:

 

I spoke with the fabricator yesterday, and the estimated price per tank will be $355.00.  Not as good as I had hoped, but not too bad compared to what the average speed shop charges for something you wouldnt buy anyway.  Back in 2007, the going rate for a rectangular tank made from whatever left over aluminum plate I have on hand was $350.00 to $400.00.  

One reason the price is a bit higher than all three (3) versions of Lotus Europa tanks the shop makes for me, is that the Peerless tank has two internal baffles.  The other is volume.  I committed to buy 25 units each of the Series 2 and Twin Cam tanks [and actually exceeded those numbers]. 

We are proceeding with a pair for Deans car in April, and I will post pictures when they are finished.  I will also be able to package and weigh one, then, to determine a firm price for shipping overseas.  [Should be around $60.00 per tank or less]. 

Kind regards,

Steve in Ohio



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NIGEL C

Date:

Hi Ohio Steve!

 

That all sounds interesting. I did get my tanks built over here in Ali but not sure if the guy still does this kind of work. will check.

Just thought I would mention that I had the pick up points moved on my tanks. At the time I was living at a house with a very steep driveway. I thought that when the car was finished (ha ha still isnt!) and I started it up on the drive, if the tanks were not full then it could run out of fuel because they are so long.

So I had one pick up at the front and one at the back. So depending on which way Im parked I always have the best option to get fuel. It has proved most useful!

I also went down the scrap yard and found a suitable filler neck (x2) from a diesel estate car. This means I have a very short piece of flexible pipe from the tank to a steel filler pipe. This pipe also had a breather pipe welded into it that comes up just below the filler cap.

I dont get any smell of fuel in the boot or in the car.

And why a diesel donor car. Well whilst I was looking I found that most petrol cars filler pipes were rusty where as diesel cars were sound. The reasoning I came to was that the petrol keeps washing them clean, whilst the diesel is oily by nature?

 



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Steve in Ohio

Date:

Nigel,

Very keen of you to think about the fuel pick-up issues involved with shallow tanks.  And I like the solution, too.  Now you're in good shape whether you'are going uphill or downhill. 

But I thought the Peerless set-up was somewhat like the mid-'80s XJ6 Jaguars, where you switch from one tank to the other.  Yave you joined your tanks with a balance tube or ???

Steve



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Steve in Ohio

Date:

Nigel and all,

I forwarded your concerns and solution to Dean.  He may opt for an additional drain plug bung at the forward end of each tank.  That way, each owner can decide whether or not to use it as a supply for the fuel pump(s) and carbs or as an extra drain. 

It's less expensive than adding another pick-up tube. 

Kind regards,

Steve in Ohio



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Till

Date:

Hi Nigel

Not a really important thing.... - a good steel filler pipe on your car is important!

But i really belife it`s the other way around. the diesel don`t protect the steel - it´s more that the petrol attacks the steel. oh my god, my english......

 

best greatings

Till



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nigel c

Date:

hi steve, no I dont have a ballance pipe and yes I switch from tank to tank on a regular basis...as I cant afford to fill either of them!disbelief

 

Till, your english is just fine!biggrin



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Steve in Ohio

Date:

End panels and body panels have been laser cut.  Scheduled for forming - bending the body panels - and welding next week.  I hope to have pictures soon.  Stay tuned .....

Kind regards,

Steve in Ohio



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Steve in Ohio

Date:

 

Here are the links to pictures of the tanks.  I think they came out very well.

 

http://www.flickr.com/photos/62775701@N06/5759997930/in/photostream

 

http://www.flickr.com/photos/62775701@N06/5759996590/in/photostream/

 

http://www.flickr.com/photos/62775701@N06/5759995326/in/photostream/

 

http://www.flickr.com/photos/62775701@N06/5759451851/in/photostream/

 

Let me know if there are any questions. 

 

Cheers,

 

Steve in Ohio



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Anonymous

Date:

Sorry, everyone.  Can't post pictures - can't post links to pictures.  Latest hurdle is that my posts are identified as Spam.  Go figure.

If you think you might want to see how Dean's tanks came out, email me directly.

steve.veris@sbcglobal.net

Cheers,

Steve in Ohio



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Steve in Ohio

Date:

Here is a link to pictures of Dean's tanks, which were shipped to him today:

http://www.flickr.com/photos/62775701@N06/

Cheers,

Steve in Ohio



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Atle Granby

Date:

Hi Steve

Nice tanks!!!

Is it possible to fabrikate a set for me, ans send them to Norway?

If so, please tell me the total price.

 

Best regards

Atle Granby



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Steve in Ohio

Date:

Atle,

Thanks for your interest.  I have shipped smaller items to a Lotus owner in Norway who has a Europa and an Elan, but never any really large items.  Send me your address and I will calculate the shipping cost for you:  steve.veris@sbcglobal.net

Cheers,

Steve in Ohio



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Steve in Ohio

Date:

I just checked on the shipping.  For International Priority Mail - the least expensive way to ship using our postal service - each tank would be US $ 76.50.  I had to have the boxes made for Deans' tanks, and they each cost US $ 15.95.  I might be able to buy larger boxes from UPS - then cut them down to fit the tanks.  But it would only save a few dollars. 

I guess it is because of the length of the box.  no

Steve in Ohio



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Atle Granby

Date:

Steve, you are the best!!!

After some days e-mailing we got all the info needed for making new petrol tanks for my car. This is giving me a needed boost in my project.

 

And thank you Gary for the info regarding the paint job. My hope is to get the car painted this summer, and get the interior back in the car in the wintertime. Then, maby, I will get the car back on the road next summer.

Only missing som info regarding the screens.....

 

Best regards

Atle Granby

#153



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Steve in Ohio

Date:

Atle,

Thanks for the kind words.  I've only seen one Peerless GT in person, at a car show last year here in Dayton.  A nice restored example in green. 

The fabricators will start on your tanks as soon as they complete 4 that are in process that fit Lotus Elans. 

Cheers,

Steve in Ohio



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Steve in Ohio

Date:

Atle,

Your tanks are packed and ready to ship.  Please let me know how you like them after they arrive.  I hope it doesn't take too long via USPS Priority Mail International.  Our post office says it will take 6-10 business days. 

Kind regards,

Steve in Ohio



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Atle Granby

Date:

Hi Steve

As you alredy know, the tanks has ariwed to me. And they are just what I needed on my car.

The welding is fine, the tanks looks fine on the car and the weight is aprox 1/3 of the steel tanks.

 

If you look at this link, you maby able to help others? : http://www.tr-register.co.uk/forums/index.php?showtopic=31060&pid=227896&st=0&#entry227896

 

Best regards

Atle



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