Taking a little break from work to work on the gas tank, might be a short lived break though! I cut the passenger side end of the tank out this evening and it fits up real nice. Also notice the seams are all cleaned off to bare metal. Hot rolled steel has a surface coating on it that really ought to always be ground off before welding. I don't always do that but in this case it will be done. I want to make sure my welds don't have any impurites in them as best I can and this is one way to do so. Some of you may be wondering why the holes are not cut in for the filler and vent. I'm using a YJ tub and the filler is located on the driver's side. I like it on that side so instead of moving the filler on the YJ tub to match that of a CJ I left it alone.
Here's the fit I want for all the seams. The corners for a V that will be filled with weld. It'll make for a nice looking weld that really won't need any clean up at all and it's much easier to weld than if the ends were allowed to be fluch where all you have is the flat seam.
Here's the end tacked in place and another look at the seam. When I did the tacks I cut the heated, oxidixed end off the wire between each tack. It makes for a better tack that does not have contaminates in it and requires less heat to strike the arc. This is something that ought to be done when welding patch panels in the body too. Try it next time and see how much better the tack weld looks. Also before I weld that solid the metal will be cleaned off with a wire wheel so that I am back down to a clean surface.
I also cleaned the metal on ths inside of the tank. I may weld those seams there too. Not sure about that yet though.
I wish I had this advice before welding up my plasma table water reservoir! I had a pin-hole leak that was a pain to fix... Awesome as always, Jim!
Thanks Jim. I'm hoping not to have any leaks but won't be surprised if I end up with some.
Originally Posted by TKFireman
Looks great Jim. Nice work as always
Originally Posted by lucdog
Real nice Jim. I cut that little ball off the wire on my MIG as well, 90% of the time.
I wouldn't weld the inside of the tank, at CAT on the tank line , they don't weld them either.
I think it really depends on how much abuse you think the tank will have. Are you going to use a baffles in the tank?
Thanks Bill. I'll weld the outside first then if that turns out good I likely won't weld the inside fillet. There will be two baffles equally spaced running parralell to the frame. I have some 14 gauge steel that I'll use for them.
Originally Posted by CJ7ROB
Nice work Jim. Do you need to use a sealer on the inside and when welding the last piece how do you make sure no wire passes thru the groove and into the tank?
Thanks Rob. I'm going to do some checking on the sealer. It seems like a good idea but I'm going to call some of the manufacturers to see what they can tell me first. If the top fits right there won't be a gap for wire to pass through. I'll just have to be extra careful in cutting and fitting it.
Monday I decided to do the final work on the block before I took it to the machine shop. Thanks to Dave and Bill for giving me the nudge.
I took all of the freeze plugs out and cleaned the gasket surfaces. I also ground off some of the roughness off from the casting process. The engine showed very little signs of wear but when I took the freeze plugs out the water jacket was full of sludge. Enough to have clogged up a radiator. No doubt there'd been overheating problems. This alone made me glad I tore the engine down. Not yet sure whether the block will be bored or not. One cylinder was .004 oversize and after honing that might not work out. The rotating assembly is going to be balanced too. Going to polish the crank and chamfer the oil passage holes in it. They also have the heads and will just be grinding the valves and seats. I checked the deck surfaces with my straigh-tedge and they all looked good.
Our engine rebuilders only use furnaces here to clean out all that old sludge. At the moment, as my 302 is also about to get a going over..., I wish there was a place with a caustic dipping pool to eat all that garbage away. My Explorer 302 came from Georgia, so it has seen lots of humidity and heat, too.
Why not weld the inside seams of your tank? You'll have it open so it's double the insurance, isn't it? Just asking.