Vin Rouge
11th September 2010, 05:23 PM
Here’s my response to the requests for details of the gas tank holder I recently finished making (with some help from Mick [Killer] who did the welding - thanks Mick). The frame was made to suit a 2kg tank with a diameter of 210mm.
Materials are:
- 2½ metres 20mm x 20mm box section steel
- 1 metre 40mm x 1.5mm steel strap (I couldn’t get 1.5mm so used 3mm which worked OK)
-½ metre 40mm x 40mm x 3mm angle
First I knocked up a wooden frame and cut the box section to fit. There’s two parts to make:
- The frame (five pieces)
- The brace (three pieces that support the bottom of the tank)
A length of studding was tapped in. This provides the single fixing. I also drilled holes to allow air to escape during welding. I found that cutting 45 degree angles with a hacksaw to be a bit fiddly and needed to finish with a file. Sizes are:
- Height – 520mm
- Width – 22mm
- Depth (the two side pieces that with the cross piece make the brace) 13mm
Next I made the octagonal strap. I measured and marked eight sections of 88mm, then made a 45 degree bend at each mark to end up with an octagon. I had already made a metal bending machine so this was relatively easy. However, it should be possible to make the bends in a vice. The two end pieces were later trimmed back to suit the latch.
The two side supports were cut from the leftover strap.
Finally, two brackets were made from the angle. The top bracket required a lot of hacksaw work to reduce one side of the angle to just enough to raise it above the gutter (approx 15mm). This bracket runs the full width of the gutter and when welded in place positions the frame. The bottom bracket was made to use holes already cut for the rear wheel carrier. To ensure that everything lined up properly, I cut the hole for the fixing bolt after everything was welded up.
After welding the latch was fitted. I tapped threads into the strap, screwed on the latch, cut the screws and riveted them over.
Then finally some paint, line the inside of the strap with rubber and fit it to the Defender. It took about six hours to make.
Materials are:
- 2½ metres 20mm x 20mm box section steel
- 1 metre 40mm x 1.5mm steel strap (I couldn’t get 1.5mm so used 3mm which worked OK)
-½ metre 40mm x 40mm x 3mm angle
First I knocked up a wooden frame and cut the box section to fit. There’s two parts to make:
- The frame (five pieces)
- The brace (three pieces that support the bottom of the tank)
A length of studding was tapped in. This provides the single fixing. I also drilled holes to allow air to escape during welding. I found that cutting 45 degree angles with a hacksaw to be a bit fiddly and needed to finish with a file. Sizes are:
- Height – 520mm
- Width – 22mm
- Depth (the two side pieces that with the cross piece make the brace) 13mm
Next I made the octagonal strap. I measured and marked eight sections of 88mm, then made a 45 degree bend at each mark to end up with an octagon. I had already made a metal bending machine so this was relatively easy. However, it should be possible to make the bends in a vice. The two end pieces were later trimmed back to suit the latch.
The two side supports were cut from the leftover strap.
Finally, two brackets were made from the angle. The top bracket required a lot of hacksaw work to reduce one side of the angle to just enough to raise it above the gutter (approx 15mm). This bracket runs the full width of the gutter and when welded in place positions the frame. The bottom bracket was made to use holes already cut for the rear wheel carrier. To ensure that everything lined up properly, I cut the hole for the fixing bolt after everything was welded up.
After welding the latch was fitted. I tapped threads into the strap, screwed on the latch, cut the screws and riveted them over.
Then finally some paint, line the inside of the strap with rubber and fit it to the Defender. It took about six hours to make.