"Rich S." wrote in message
...
"Fortunat1" wrote in message ...
Yes, you would wrap the sheet to form the overall tank shape, weld in
a baffle or three working from the open ends and then weld on the ends
to close things up.

'Kay. makes sense. Al I have to do now is learn to weld aluminum!

Or, you can drill holes in the outer skin where the baffle flanges are
located and then weld them from the outside. It's a lot easier than trying
to get a stinger in the tank.

Learn how to weld Aluminum? After a couple thousand in dedicated
equipment, and a hundred hours of practice, you'll certainly be qualified.
It's a little easier than turning crankshafts, I suppose. If it was me,
I'd spend my time doing fun things and leave the 20 minutes of welding to
the pros.

Rich S.

It isn't all that bad, Rich. I use the same Smith torch and tanks for
aluminum as for steel. Use an aluminum flux and soft aluminum filler rod.
I would use a cheap spot welder to tack in the baffles. They work great on
aluminum.

Leave your outside seams as bent out flanges. Brush a little flux on the
flanges and melt them together with the torch. It really isn't terribly
tough. The flanges melt down and you don't even need filler rod! See the
Tinman videos on welding aluminum with a torch.

Highflyer
Highflight Aviation Services
Pinckneyville Airport ( PJY )