IF you can weld.... this is always an option.

How to Make a Gas Tank
Contributor
By Steve Smith

eHow Contributing Writer

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A gas tank is a necessary part of a car or any other vehicle that uses a combustible engine. Tanks are generally made of metal, but some are also made of fiberglass and high-density plastic. You can make your own gas tank using metal-shaping tools and 12-gauge sheet metal and install it on a car, truck or ATV. You should be familiar with metal working and have a hydraulic press brake before undertaking this project.

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Difficulty: Moderately ChallengingInstructionsThings You'll Need:
Poster board for a template
Sheet metal
Metal cutting tools
Welding equipment
Step 1Create a template for the gas tank by tracing an area 3 feet long by 2 feet wide on a piece of poster board. The area will have straight, 90-degree corners. Place the template on a piece of sheet metal and trace around the edge with a grease pen. This will make one half of the gas tank; the other half will be made with an identical piece. Place the template on another piece of sheet metal and again trace the shape onto the sheet metal.

Step 2Cut out the shapes using a metal saw, carefully guiding the sheet metal through the saw to create a straight, even cut. If you have a saw with a guide, use it to make a better cut.

Step 3Place one of the sheets on a hydraulic metal press---6 inches of the 3 foot side of the sheet metal needs to be past the brake blade (the outer edge of the brake blade will be six inches).

Step 4Bend the metal to a 90-degree angle. Remove the sheet metal, turn it around and repeat step 4 for the other longer side. Repeat steps 4 and 5 on the other sheet. Both pieces of sheet metal will have two bent edges, making two halves of a gas tank.

Step 5Place one of the pieces on a work bench so the flat side is flush with the bench and the bent sides are facing up. Place two C-clamps on each corner of the bent sides.

Step 6Set the second piece onto the first, aligning the corners of both pieces bent sides. Tighten the C-clamps so half of the clamp is holding one side and half holding the other. This secures the two pieces together for your weld.

Step 7Create three tack welds in each side along the seams of the two pieces. With a gas arc welder and #3 filler bar. Make sure the two halves are aligned properly. Finish the weld using a gas welder and #3 filler bar. The welds must be leak-proof. Use extra filler, if necessary. Be careful when making the welds.

Step 8Measure the height and width of the openings on both sides of the gas tank. Trace and cut two matching sections from the sheet metal to build the sides of the tank. Secure the pieces to the tank with by making a tack weld first on the bottom and top edge. Complete the weld using another #3 filler bar.

Step 9Cut a hole for the petcock valve using a 1-inch metal drill bit (or larger if the petcock valve is larger). Cut another hole for the fuel line and fuel pump assembly. Use a 3/8-inch bit or metal saw for this step. Each fuel pump assembly is different; accurately measure yours to find the proper measurements and dimensions.

Step 10Attach mounting brackets. Measure the chassis of the car where the tank is going to be mounted. Cut two or four mounting brackets from 1/4 steel plates or steel channel bar to match these measurements. Weld them to the top of the tank using a gas welder and filler bar. Each fuel tank mounts in a different way to the car; you'll have to make yours custom to your particular vehicle.