Aluminium Fuel Tank Fabrication

KDM is your professional aluminum fuel tank fabrication manufacturer in China.

A one-stop solution to provide your customization based on your specifications.


KDM - Expert Aluminium Fuel Tank Fabrication Manufacturer in China

KDM has extensive experience fabricating aluminum fuel tanks for various clients worldwide. Aluminum is one of the most popular materials for making fuel tanks. It’s light, strong, and corrosion-resistant, a must-have characteristic for essential equipment.

Aluminum fuel tanks are made for automobiles, trucks, boats, motorcycles, and other vehicles. Aside from that, we also offer more durable corrosion-resistant fuel tanks used in heavy trucks. KDM has multiple advantages in manufacturing aluminum fuel tanks, which have been steadily increasing. 

KDM Aluminium Fuel Tank Fabrication

There are numerous benefits to using an aluminum fuel tank, some of which may include:

  • Lightweight and simple to install in automobiles.
  • Individual preferences can be met by customizing these tanks.
  • Corrosion-free fuel tanks.
  • When compared to alternative fuel tanks, it is both affordable and efficient.
  • Bespoke aluminum fabrication.
  • Provide great quality tanks that are quiet, highly reliable, and competent.
  • Aluminium Fuel Tank Fabrication Design Innovation
  • Aluminium Fuel Tank Fabrication Design Innovation
  • Aluminium Fuel Tank Fabrication Design Innovation

KDM Aluminum Fuel Tank Fabrication Capabilities

KDM has unmatched expertise when it comes to fabricating aluminum fuel tanks. We have the potential to accomplish several projects and products to its extended qualities and features. However, KDM uses different manufacturing processes for aluminum fuel tanks and other products.

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KDM Aluminum Fuel Tank to Skyrocket Your Business Since 2003

KDM is a one-stop solution to provide your customization aluminum fuel tank fabrication. The aluminum fuel tanks are available in round, oval, and square shapes, with mounting brackets, straps, locking fuel lids, and anti-roll bars as options. 

All specifications are only intended to be used as a reference. We’d be delighted to assist you in creating an aluminum fuel tank based on your requirements. Get a free quote by contacting us today.

How KDM Featured Aluminum Fuel Tank

KDM is a reliable source for aluminum fuel tanks. We offer thousands of aluminum fuel tanks of flexible sizes, capacities, finishes, designs, and complete customization that potentially support your business or projects.
Aluminum Center Fill Fuel Tank

An aluminum mid fills fuel tank is made from 100% highest-grade aluminum. It is assembled with extreme durability that can fill a thousand liters of fuel. 

Aluminum End Fill Fuel Tank

The aluminum end fills fuel tank is lightweight and ideal for street rod application and off-road vehicles—it features an outlet vented cap and two black straps on both sides. 

Aluminum Square Fuel Tank

An aluminum square fuel tank offers extra capacity for all fuels. It is typically less expensive, robust, reliable, flexible, and durable for more extended use. 

Gallon Aluminum Fuel Tank

The gallon aluminum fuel tank is entirely aluminum constructed and installed with a sturdy singular pickup tube. This is perfect to use for off-road vehicles and custom build.  

Baffled Aluminum Fuel Tank

A baffled aluminum fuel tank is welded to the highest quality. It is made with fully built-in baffles beneficial for preventing possible explosion and fuel surges. 

Cylindrical Aluminum Fuel Tank

The cylindrical aluminum fuel tank specializes in a breather filter mesh. It is also a cleanable and reusable tank applicable for all heavy-duty industrial applications. 

  • Aluminum Fuel Tank
  • Aluminum Fuel Tank
  • Aluminum Fuel Tank

Why Choose KDM Aluminium Fuel Tank Fabrication

You can rely on KDM’s selection of aluminum fuel tanks. This selection can also be supplemented with equipment for a more convenient and user-friendly tank installation. Some of its features include:

  • Energy-efficient.
  • Safe and highly dependable control solutions.
  • It is made of a high-quality aluminum fuel tank that is strong, corrosion-resistant, and long-lasting.
  • Characteristics that are consistent,  great dependability, and professional performance.
  • Quick-release fuel cap that is simple to use and operate.
  • Aluminum Fuel Tank
  • Aluminum Fuel Tank
  • Aluminum Fuel Tank

Aluminium Fuel Tank Fabrication Advantages

  • A fuel tank made of aluminum that is both durable and trustworthy.
  • Produced from high-quality raw materials.
  • It will protect itself until they have enough air exposure.
  • Any industrial application would benefit from this cost-effective fuel tank.

KDM Aluminum Fuel Tank Fabrication

KDM is the central eye for aluminum fuel tank fabrication. All aluminum fuel tanks are built with unequaled specifications and trademarks. It undergoes significant inspections to ensure its performance and quality consistency.  

Aluminum Auxiliary Fuel Tank
Aluminum Auxiliary Fuel Tank

The aluminum auxiliary fuel tank is designed as an additional fuel tank that add-on the fuel carrying capacity of the vehicles. Also, it is available for all sizes of diesel vehicles. 

Aluminum Diesel Fuel Tank
Aluminum Diesel Fuel Tank

An aluminum diesel fuel tank features rust-proof qualities. It is built with superior strength that stands longer and guarantees high functionality, endurance, and accuracy.

Aluminum Fuel Surge Tank
Aluminum Fuel Surge Tank

The aluminum fuel surge tank is professionally manufactured with high accuracy, consistency, and durability: high-quality tanks that offer rustproof, secure, and long-lasting qualities. 

Aluminum Replacement Fuel Tank
Aluminum Alternate Fuel Tank

All aluminum replacement fuel tanks are custom-made—available in all sizes and filling capacity that matches all industrial vehicles. It is budget-friendly and easy to clean.

Spun Aluminum Fuel Tank
Spun Aluminum Fuel Tank

The spun aluminum fuel tank is fabricated from the highest-quality premium aluminum materials, uniform finishes, and crafted style for never-ending performance and sturdiness. 

Universal Aluminum Fuel Tank
Universal Aluminum Fuel Tank

The universal aluminum fuel tank is safe for all flammable fluids or fuels: the most reliable, efficient, and cost-saving tank and an excellent solution for universal applications. 

More Questions You May Have

Aluminium Fuel Tank Fabrication

KDM offers a one-stop solution for manufacturing all types of aluminum fuel tanks. We want to make your entire business easier and more effective by easing your production process. 

Furthermore, KDM is looking forward to collaborating with you to level up your project or business. Please get in touch with us if you have any questions or concerns.


Aluminium Fuel Tank Fabrication: The Ultimate Guide

In this guide, you will find all information you are looking for about aluminum fuel tank fabrication.

Whether you want to learn about design, fabrication techniques or material grade – everything you are looking for is right here.

Keep reading to learn more

What Is Aluminum Fuel Tank Fabrication?

This is the process of shaping aluminum material into a fuel tank through welding, folding, bending, shearing, etc.

Aluminum fuel tank

Aluminum fuel tank

Aluminum material is flexible, strong, and versatile and can be made into various alloy grades. This allows it to be fabricated into a wide range of fuel tanks.

Benefits Of Aluminum Material For Fuel Tank Fabrication

Most fuel tank fabricators prefer aluminum because of its numerous benefits.

  • One of the major advantages of aluminum as a material is durability. Thanks to its corrosion resistance, aluminum has a very long lifespan.

This material is also suitable for outdoors since it is able to withstand harsh elements such as moisture, heat, UV, dust, etc.

Fuel tanks made from aluminum have a life expectancy of about 20 years.

During this time they store fuel and perform their functions without any major issues.

  • Another advantage of aluminum is its impact resistance.

This material has a high resistance to breakage, dents, punches and other defects caused by impact.

Fuel Tank Fabrication

These damages can cause leaks or deformities which then affect the overall life expectancy or functionality of the aluminum fuel tank.

By using aluminum material, the fuel tanks can deter these damages and live up to their full potential.

  • Yet another notable advantage of aluminum is the ability to be customizable.

This material is extremely flexible thus easily cut, welded, cast, machined, extruded, etc.

These versatile properties allow fuel tank fabricators to make a fuel that suits your exact needs. This includes complex designs, shapes and sizes.

  • Another benefit of aluminum material that it is very lightweight. Aluminum is such a light metal that it makes it relatively cheaper to purchase and transport.

Furthermore, the strength of aluminum can be manipulated by using various alloys to achieve either higher strength or easier formability.

  • Lastly, another advantage of aluminum material is recyclable. Contrary to popular belief aluminum is actually 100% recyclable.

Furthermore, during the recycling process, it does not lose any of its original properties. Most fabricators prefer using recycled aluminum instead of using prime metal from the ground.

It is no doubt that recycled material is more cost-effective.

Aluminum material goes further to conserve the environment as it traps significant amounts of harmful chemicals and gases.

It prevents chemicals such as sulfur dioxide and carbon monoxide from being released into the atmosphere.

Fabricating Aluminum Fuel Tank

Step 1: Designing Aluminum Fuel Tank

You’ll begin with taking the measurements of the space in which you will be keeping your fuel tank. Note that this step might be extremely time consuming.

Therefore you need a piece of paper to sketch your potential design on and note down all your measurements.

As you design your fuel tank, ensure you leave out sufficient space for additional parts such as vents, fuel fillers, sensors, mounting straps, etc.

There are various aluminum fuel tank designs and shapes to choose from.

They include: rectangular, cylindrical, tapered, belly, v-hull, etc. You can also fabricate your own custom fuel tank to suit your specific requirements.

Step 2: Build Prototype Of Aluminum Gas Tank

Now that you have completed designing your fuel tank and taking measurements, it’s time to build a prototype.

Making a prototype gives you a clear and complete idea of how your final fuel tank design will look like.

Prototyping also allows you to streamline your design process and ensures you are not missing any important details.

The easiest way to build a fuel tank prototype is by using cardboard materials. With that being said, follow the following simple steps:

Using all the measurements from your designs, construct an exact cardboard fuel tank model. Ensure that your cardboard prototype contains all the actual pieces that you will cut from your aluminum material.

Use a tape or any other strong adhesive to put together the cardboard model into your desired shape or design.

Make sure that the prototype fits into the space you intend to place your fuel tank.

Step 3: Fabricate Actual Fuel Tank

Cut Aluminum Sheet

When cutting the aluminum sheet, ensure to replicate all the pieces according to your cardboard prototype.

Cutting aluminum may be quite intimidating. Here are a few easy, safe and practical ways on how to do it:

  • Use saw ( with carbide-tipped blades)

This is especially most suitable when you are dealing with thin aluminum sheets.

Before cutting, that you lubricate your blades. Lubricants such as standard oil or saw wax can do.

However, WD-40 is the recommended and standard lubricant for cutting aluminum.

Lubricating prevents any sparks or spillage since you are cutting metal on metal.

For best results, ensure to reduce the diameter of the cutting tool. The slower the cutting speed the better.

Fabricating Aluminum Fuel Tank

Before proceeding to cut aluminum, ensure you tightly secure it using a C-clamp.

When cutting the aluminum sheets, feed the aluminum through the blade or the other way round.

Hold the cutting saw firmly and apply pressure as you move it along the aluminum sheet.

As stated earlier ensure you work slow, steady and apply pressure evenly.

  • Use a cold chisel

You will need to determine the width of your aluminum in order to select the most appropriate chisel size. You should sharpen your chisel to about 60 or 70 degrees.

Ensure that you secure the aluminum piece tightly on a strong bench vice before you start cutting.

As for cutting start by holding the chisel tip against the aluminum sheet.

Proceed to use a harmer to strike the handle of the chisel making sure that you are doing so perpendicularly.

cutting aluminum sheet

cutting aluminum

Proceed to strike the aluminum sheet until you get a notch. At this point you have already cut your metal.

This process should take you about 30 seconds. If it takes longer you may be using the wrong chisel size.

Forming Aluminum Sheet For Fuel Tank

This step involves bending your cut aluminum to form the shape or design you want for the fuel tank.

Aluminum is quite easy to bend as it is very malleable.

However, you need to do it carefully to avoid cracking or fracturing it. The following are techniques you can use to bend and shape aluminum:

  • Using a metal bending brake
  • Using a arbor press
  • Using a heat torch

Welding Aluminum Fuel Tank

It’s worth noting that aluminum can be quite difficult to weld due to its unique properties. You may encounter challenges such as hot cracking and porosity.

To achieve the best welded results ensure that you select the right filler metal.

It should be high in strength and toughness, corrosion resistant and have a low crack sensitivity.

You should also clean the aluminum sheets thoroughly before you start welding.

welding Aluminum fuel tank

welding Aluminum fuel tank

 Ensure to also remove the oxide layer off the aluminum before welding. This can be done using a stainless steel brush.

Before you begin aluminum welding, you need to secure fuel tank by clamping in as many spots as possible to keep it in place.

When welding, you should not just work on side and then leave it; you need to set the fuel tank up and tack weld it before moving on.

Before you start welding the final parts of the tank ensure that you tack weld together all of the tank.

To prevent your tank from warping, take occasional breaks to let it cool.

That being said there are various techniques you can use to weld your aluminum fuel tank. These are:

Gas Tungsten Arc Welding Aluminum

This is also known as Tungsten Inert Gas welding and is the most common for technique for aluminum welding.

This method involves feeding the filler material into the puddle by hand. Note that it does not need mechanical wire feeding.

Gas tungsten arc welding

Gas tungsten arc welding

This method of welding is popular it produces clean and new welds. It also prevents any sort of contamination of the work station by the atmosphere.

Arc Welding Aluminum

This method of aluminum welding uses a power supply to melt and join the aluminum pieces.

It is a little bit complicated and should be done by an experienced and well trained welder.

Other methods of welding aluminum are resistance welding, laser beam and electronic beam welding.

Arc welding

Arc welding

Step 4: Inspect Aluminum Fuel Tank For Leakages

A sure way of checking if your fuel tank has leakages is by pressure testing.

Some people make the mistake of using water, but this does not discover small pin holes that is why pressure testing is recommended.

Drill a tiny hole and apply pressure to the tank. Then apply a little soap and water on the welded pats.

When you apply pressure to the tank, leaks if any will show themselves.

Testing for leaks is such an important step and you shouldn’t skip it. Leakages in a fuel tank can be disastrous.

Step 5: Install Aluminum Fuel Tank Accessories

The final step is to install the accessories of the fuel tank.

Aluminum fuel tank accessories are the pieces that allow the movement of fuel in and out of the tank.

The aluminum fuel tank should have the following accessories: fuel gauge sender, vent, fuel filler neck, return, and fuel pick-up and fuel level sensor.

Aluminum Thickness For Fuel Tank

The recommended aluminum thickness for small fuel tanks should be a minimum of no less than 0.90 inches.

For bigger fuel tanks, the aluminum thickness should be a minimum of no less than 0.125 inches and a maximum of no thicker than 0.250 inches.

Aluminum Alloy Grade For Fuel Tanks

Pure Aluminum is a relatively light weight and soft material. It is combined with alloying elements to give it mechanical properties such as strength and weldability.

Types of aluminum alloy grades suitable for fuel tanks is the 5000 series; specifically 5086, 5083 0r 5052.

These are strong alloys which are weldable and not prone to cracking.

Uses Of Aluminum Fuel Tank
  • Storage- the primary use for aluminum fuel tanks is safe storage of fuel. Aluminum tanks are used in vehicles such as cars, boats, trucks, motor bikes etc.

The fuel tank holds a particular amount of fuel depending on the size. A fuel pump feeds the engine of the vehicle with fuel from the fuel tank.

Aluminum Fuel Tank

Aluminum tanks are durable, corrosion free, cost effective and easy to install which makes them ideal for vehicle fuel tanks.

  • Determining fuel level- an aluminum fuel tank consists of accessories such as fuel gauge sender and fuel level sensor among others.

These provide a way of determining the quantity of fuel remaining in the fuel tank. A fuel level sensor indicates when the tank is empty and need a refill.

  • Transportation- aluminum fuel tanks are used for safe transportation of fuel such as petrol, diesel or other flammable liquids.

Moving fuel from one place to another can be tricky because of their flammable nature.

Once enclosed in aluminum fuel tank, the fuel reaches its destination without experiencing any risky hazards such as leakage or combustion.

Surface Finish For Fabricated Aluminum Fuel Tank

Surface finishes are usually applied to fabricated aluminum fuel tanks to provide protection, increase durability or simply for aesthetic purposes.

Surface finishes can improve the conditions and properties of a fabricated aluminum fuel tank.

They can also be used to enhance the appearance or alter the hardness of the surface.

The main type of surface finishes for an aluminum fuel tanks are as follows:

  • Anodizing- naturally, aluminum material and its alloys have a hard and inert surface oxide layer.

Anodizing is basically an electrochemical process that adds more protection beyond that natural oxide layer.

This surface finish not only prevents the fuel tank from corrosion but also enhances its durability.

Anodizing aluminum gives it a great protection against UV making it perfect for outdoor or other places with UV exposure.

Because it is UV resistant, an anodized aluminum fuel tank will not fade over time.

The anodized layer will also not flake or peel off unlike other surface finishes.

Anodized aluminum fuel tanks are however limited to matt or glossy finishes since they are translucent.

They are easy to take care of through regular cleaning with mild detergent and clean water.

You should be careful not misapply anodizing as it can produce a poor quality surface finish.

  • Powder coating finish- this is done to add on to aluminum’s corrosion resistance, increase its wear resistance and for aesthetic purpose.

If not properly, powder coating could potentially harm aluminum.

The correct process is pretreatment, powder application and curing.

During pretreatment, clean the fuel tank thoroughly to get rid of all dirt and impurities.

Impurities can affect the adhesion of the powder to the surface thereby ruining the finish.

Aluminum Fuel Tank

Before powder application, the aluminum oxide is stripped from the surface. The surface made rough in order to improve its adhesion capabilities.

Powder application involves flinging electrostatically charged particles at the surface of the fuel tank.

The aluminum fuel tank should be electrostatically grounded to allow the powder particles stick to the surface better.

After the powder coating is complete, the next step is curing. This involves heating the fuel tank at desired temperatures for a particular amount of time.

This usually depends of the powder and coating thickness.

Powder coating is available in various finishes such as gloss, matt, super matt, high gloss, satin and textured.

It is also available in a variety of colors and color gradients.

  • Liquid painting- this aluminum surface finish is also used for protective as well as aesthetic purposes.

This type of finish has a more colors to choose from than any other process. It also has a wide variety of types of paints to choose from.

It is easy to create a custom color for your aluminum fuel tank when using this surface finish type.

I know you may also be interested in:

Aluminum Sheet Fabrication

Aluminum Powder Coating

Aluminum Bending

Aluminum Polishing

Aluminum Stamping

For all your aluminum fuel tank fabrication, contact us now.

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