planning on making an alluminium petrol tank but can t find any reference anywhere as to how thick the alluminium needs to be . Is there a reccomended thickness or a minnimum requirement for the iva ?

Ive used 3mm ally for mine as i think anythink thinner just wouldent be suitable for a fuel tank.

How thin can you weld with out blowing holes and distorting it ?

1.6 for mine.

2mm for mine!

If you swage the thin metal it will be stiffer, we are at 1.6

Its not the thinness or thickness but the way its put together, that makes it strong.

running a few ribs with the swager makes a difference.

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Originally posted by mangogrooveworkshop
running a few ribs with the swager makes a difference.

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Thanks everyone . some good advice.

does it make much difference to the weight? i have a green one that just needs fitting, not sure if it is worth the work though

Mine is 2mm, with the fliddly bits: sender mount, filler neck, being 3mm. I had to weld most of it myself with a tig, and it doable without too much distortion.

2mm for my old one - remember when you need gaskets to seal etc - it needs to be flat - thin can make it harder as it may bend a bit

weight wont really be an issue unless your racing