[larrybuck]

To busy paws: I had a friend custom build it from scratch. I started w a flat plastic sheet about 1/4" thick; 4X6 feet. He cut out a bottom, top, and 2 or 3 layers of bands height wise, and slowly plastic welded it altogether. It was time consuming, and much ventilation (outside) is needed, as plastic smoke is a little nasty. I'm sorry that I can't remember the exact name of the particular type of plastic I used; but if you explain to the plastic supply store what you are trying to do, they will point you to the right type!

I admittingly, am not super hands on; at $20. per hr., I paid my friend about $200. I started w a weeny powered welder at first; thats what ran into so many hrs.

The stock tank on my VW is plastic; strong, lightweight, will never rust; so I figured a 2nd tank built in same to be good.

So mine is a one off; that I am proud to own even if I didn't make it myself. For precautions, we put a layer of plastic sheeting between the tank and spare depression to prevent any rubbing. He also added a small metal bracket on top of the tank, so a holder could be attached to just the upper side in one place on the edge of the depression. This was to prevent any TWISTING of the tank that might be done in emergency driving. This method does not really have to be any more sophisticated than like the screws used to keep a light globe in position in your home.

I really like the stock depressions for the low center of gravity, a just a natural safety feeling. If you are only going to build a 5-6 gallon one, you could build it low enough to still have a spare halfway in the depression above it if you choose; although especially if this is a gasoline situation for you and not diesel; for obvious reasons, I'd reccomend some kind of padding between.

For possible emergency driving, I think a tank should be near the circumforance of the depression, as opposed to something box like that might need lots of spacers, or other ideas to keep it from sliding around. I suppose something like the battery hold-downs (universal) would do; but it is nice to have something that looks professional.

Again, my app was diesel, so my venting concerns were min., so please keep that in mind for your safety! The color of the sheet I got was white; I thought a good color for keeping heat down.

In my app., I had heated lines running under the car toward the eng. compartment, as I was trying to do Veggie!
I didn't get far enough to figure out a gauge sender or any of that. When my friend finished the tank; before I could even say a word, he WHALED on the tank w a hammer showing me how strong it was!

If you buy a good quality welder, and since you are only looking for 5-6 gallons, whether you choose to try it yourself, or pay another, enough people are looking for work that you could probably find a Mobile Mechanic type guy in your local Craig's List that would be reasonable dollars per hr. wise.

Racing type fuel cells are very expensive I think in comparison. Just be safe, as again I'm mostly concerned about proper venting for a gas app.


To Joenavy85: I think I enjoy driving about the same # of hrs. per day as you do. I do try to break it up a little w basketball shooting, or walking to keep the sitting stiffness down.

To Old Teleman: I surmise that all those miles and hrs. were done when you were a wee bit younger. If I'm VERY comfortable in my alignment posture wise w steering wheel, correct distance of arms out; I love up to 13 hrs. a day at 50-55 mph.
I tried 22 hrs. on a motorcycle when much younger... felt tired enough to feel like I was on drugs or something.. the enjoyment factor is gone at that point for me.

At 30 yrs. old, I could do 800-950 miles per day at 55mph. for 4 days in a row, but now, unless I ride alot to TRAIN my butt, 500 miles is long, and 250-300 at 50-55mph. I enjoy much more. Unless you have the perfect custom seat, or are much shorter, I don't see how these guys did these Ironman 1,000 miles a day back to back to back trips, until I just now realized........... I've been an Ecomodder for yrs., because I never cruised above 55mph.!!!! Those miles would go a lot faster at 80mph., or something, the adrenaline rush, and looking for cops all the time would probably keep them hyped up!