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Thread: need help with aluminum fuel tank bung

  1. #26
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    Feb 2007
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    Re: need help with aluminum fuel tank bung

    It is overkill, but the material was in stock and I didn't feel like wasting time on unneeded machining. It does not hold the part tight up against the sheet metal. I tack one side, then push down or clamp on the opposite side then tack again. You could probably put an additional lip on the bottom piece that would just leave a few thou gap between the sheet metal and the steel part, but then you would have to leave it loose and tighten up the steel parts after inserting it into the tank. You would probably have to put a couple of flats on the top part to be able to tighten it down good.

  2. #27
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    Re: need help with aluminum fuel tank bung

    So what does that part do you made? Just keep it from distorting? If it did clamp down that would be cool and a time saver from trying to hold it down with something and hope it's lined up

  3. #28
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    Re: need help with aluminum fuel tank bung

    I use Sweet Performance and or Pro werks too.
    www.tjsperformance.com
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  4. #29
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    Feb 2009
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    Re: need help with aluminum fuel tank bung

    Pro werks caps are so expensive
    Torchmate 2x2 CNC with Flashcut CNC controls
    Hypertherm Powermax45
    Esab ET220i
    Razorweld 195 Mig
    Razorweld 200ac/dc Tig
    Tormach 770, Tormach xstech
    Razorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer

  5. #30
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    Feb 2007
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    Re: need help with aluminum fuel tank bung

    Do you have a recommendation for a cheaper option with the same quality?

  6. #31
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    Feb 2009
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    Re: need help with aluminum fuel tank bung

    Size?
    I don't like vibrant caps. They leak
    Torchmate 2x2 CNC with Flashcut CNC controls
    Hypertherm Powermax45
    Esab ET220i
    Razorweld 195 Mig
    Razorweld 200ac/dc Tig
    Tormach 770, Tormach xstech
    Razorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer

  7. #32
    Join Date
    Mar 2010
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    Re: need help with aluminum fuel tank bung

    Quote Originally Posted by vpd66 View Post
    Dumb question. Where are you guys purchasing these aluminum bungs from???
    Petersen Fluid Systems, well known for dry sump systems, pumps and tanks and other cool parts CNC machines their fuel tank/oil tank fittings and makes a very nice part for this application.

  8. #33
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    Mar 2010
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    Re: need help with aluminum fuel tank bung

    Quote Originally Posted by LimitedSlip7 View Post
    Thanks for posting this. While everyone that welds these may not want to take the time to make one or even use one, I really like your thought process and implementation. The way you figured out how to get it out when you were done is cool.

  9. #34
    Join Date
    Mar 2015
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    Re: need help with aluminum fuel tank bung

    I have 2 more bungs so ill give it another shot over the weekend. hopefully the advice here will get me to success . I think what ill do is 4 tack welds and make sure the cap screws in then split the 4 sections in half again. maybe even pause half way through to be sure it isn't overheated. with practice im sure this stuff can be done with the eyes closed but my welding skills are not nearly that good

  10. #35
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    Mar 2015
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    Re: need help with aluminum fuel tank bung

    im disappointed to say the second bung was a failure. had four tack welds and all was fine at the that point. worked in small increments from there and at some point the wheels fell off. ended up like a oval again. this particular bung is so thin I think ill need a pipe or socket in there to hold the shape and possibly a tap to chase the threads afterwards. I welded in three other bungs with no problem but theyre thicker and I think that made all the difference

  11. #36
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    Re: need help with aluminum fuel tank bung

    Are you using enough amps to move briskly or trying to go slow?

    If you go slow with low amps, it will heat soak the part.
    Dave J.

    Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~

    Syncro 350
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    Tried being normal once, didn't take....I think it was a Tuesday.

  12. #37
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    Re: need help with aluminum fuel tank bung

    How are you removing these after they warp?
    Get a big piece of copper, weld smaller sections and let it cool completely between passes
    Torchmate 2x2 CNC with Flashcut CNC controls
    Hypertherm Powermax45
    Esab ET220i
    Razorweld 195 Mig
    Razorweld 200ac/dc Tig
    Tormach 770, Tormach xstech
    Razorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer

  13. #38
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    Mar 2015
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    usa
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    Re: need help with aluminum fuel tank bung

    i just grind off the weld and pry out the bung . maybe i was going to slow. ill keep trying until i get it

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