Welding / Cutting a diesel fuel tank

RBoots · May 10, 2016

Has anyone ever had a diesel fuel tank
explode, or heard of one doing so? I will
need to take a corner out of the fuel tank
on our IH 826 to install a turbo set up.
I've welded/brazed a few diesel tanks before
and never had a problem, with no special
precautions. I guess as I get older I start
to think about safety more than I did in
years back. I would never weld a gas tank,
but I guess with diesel I just always
figured it didn't burn like gas if you throw
it on a fire.

Ross

Charllie in MO · May 10, 2016

Water or vacuum cleaner? Just a thought, be careful.

Andy Martin · May 10, 2016

I think it is a hoot that diesel vehicles have the same safety warning as gasoline vehicles. But try to light a brush pile with diesel only.

Vapors can be explosive with high enough temperatures or diesel engines wouldn't run. Welding obviously creates much higher temperatures than a match, there is the possibility that you have a proper combustible mixture in the tank and it could explode. The combustible range is more narrow with diesel, so many people may have gotten away with welding on them through luck. Best to steam it out or fill with water just like you would a gasoline tank.

markct · May 10, 2016

Vacuum cleaner????? Like as in suck the vapors out of the tank and thru the spark producing brush type motor that most use?Might not end well!

Janicholson · May 10, 2016

How about just using a ball peen to hammer form it into shape. Jim

Charllie in MO · May 10, 2016

Used to do it on gas tanks, that's not saying I advise it, be safe.

Ian Beale · May 10, 2016

Remember when they used to blow as well as suck? Not sure of modern ones.

centash · May 10, 2016

Have one eyebrow a bit shorter than the other from welding a truck's gas tank filled
with water. At least it held a few gallons more afterwards! Ben

RBoots · May 10, 2016

Well, I was told I could use a tank off a 1206 as they are shorter (just what I was told) to clear the turbo. No one around here has a 1206 tank and it seems anyone that does wants $2-300 if the do. From what I can remember the last time I measured it, I would have to go about 6-8" rearward from the front of the tank, and about 6-8" in towards the side opposite the manifold in a semi-circular shape if viewed from above.

Ross

RBoots · May 10, 2016

Not funny, but interesting to hear about. Do you think the vapors all got concentrated at the top and flashed off at once? How long did it allow you to work at it before igniting? I soldered the "bowl" of a Super 55 gas tank where the sediment bowl screws on back on for my dad a couple weeks ago. I figured I was fairly ok with that one as dad bought it from a guy after the sediment bowl dripped on the ignition or something and lit the gas tank on fire until it burned the entire tank of gas out of it. Melted the sediment bowl off and the solder out of the soldered seams at the bottom. I figured it should have burned out with the fire if there was anything flammable left in it.

Ross

VicS · May 10, 2016

I drove a tanker truck for years. Had a few cracks in the aluminium. Hauled gas diesel and oil. Went to certified welders. To get repaired. Truck had 5 tanks with double bulkheads. They had a big air blower. Looked like a big turbocharger. They worked in a roof only shed. 6 in. Pipe above truck with five 4in. Soft hoses to put into tanks.also 4 shop vacs. With small hoses to blow between bulk heads. Then opened all bottom valves. Then went for a long coffee break. When air coming out bottom smelled fresh. He crawled inside and welded till got Smokey. Then I would put 4" hose back inside. Had to pull it out to weld. Would blow his arc gas away. I have welded gas and diesel tanks since. Always blow for a couple hrs. Or till no smell. Only safe way. On a 18000 gal gas tank he blowed it for 24hrs.

jeffcat · May 10, 2016

If you move enough air the mix will not be explosive. Gasoline I would shy away from but diesel is a lot less Kaboomable.

showcrop · May 10, 2016

The drain flange on a tank was leaking so I siphoned the fuel out, removed the tank, turned it upside down and resoldered the fitting back on. The leftover fuel did catch fire and burn, but the only problem was the soot left behind.

Bob · May 10, 2016

If you are determined to try out for the Darwin Award, at least give you self a fighting chance of survival and steam it out, then flow inert gas through it while you muck with it.

(That is ASSUMIKNG you have no kids!)

Tubacase47 · May 10, 2016

My dad and I had a leaky diesel tank on a 930 Case. He steamed it and then welded it.

RBoots · May 10, 2016

Yeah, no kids, just me. I guess I've just been lucky with the others. So far I've just had experiences such as Showcrop, just a little diesel fire and smoke.
I'll probably wait until after we get done farming with it this spring, it works just fine the way it is, we use it on the rock picker and odd jobs. (If it would quit raining )
Ross

Stephen Newell · May 10, 2016

As long as it isn't sealed where it can build up gasses I can't see a problem. I've completely cut the bottom out of a gasoline tank before and welded sheet metal back with very little problems. When the gas ignites it just makes a little noise coming out the sending unit hole.

centash · May 10, 2016

Filled it twice with water, there must have been a small pocket of gas that didn't get flushed out. Explosion came through the fill pipe, didn't damage the tank other than swelling it up, singed some hair but no serious damage. I was told the safest way was to let exhaust fumes purge the tank while welding, so there is no oxygen in it. Ben

Andy Martin · May 10, 2016

The safest way is to have a meter that reads the flammability of the vapor in the tank. Steaming and exhaust gas work but only if they've displaced the flammable vapors below the lower explosive limit. You can't know that for sure unless you have an accurate meter to prove it is safe. The poster that advised it is safe to weld on gasoline tanks and just let them burn a little has been lucky and should talk to some widows to get a reality check.

Ian Beale · May 11, 2016

Word around here is don't try it with diesel exhaust

Ian Beale · May 11, 2016

And the only hot diesel problem I've heard of was an Allis HD 21 with a diesel converter refueling in the dark after a heavy day on the end of a chain. An eyebrow problem when the level was checked with a cigarette lighter but nothing worse.

ohiojim · May 11, 2016

if available in your area a piece of dry ice will solve your problem

tim s · May 11, 2016

"Kaboomable"....I like the that Jeff,, a new word for me ;^)

Leroy · May 11, 2016

Think all shop vacs still do. Don't think any house vacs do.

hd6gtom · May 11, 2016

yes, diesel tank, that a scrap man was cutting up-- in town-- had not been used for 20+ years old railroad fuel storage tank. he started a grass fire, fire dept was called and put out the fire. They told him to stop cutting on the diesel tank, he ignored them, tank blew up seconds after he started cutting on it, killed him and 1 young fireman. That young guy left a wife and 2 young kids, maimed the scrap mans son in law, and seriously hurt more firemen. 2 widows, others maimed for life, for what, a few dollars in scrap???????? Steam it out good and then steam it more. Fire department sued his estate and, I heard, got what little he had.

NCWayne · May 11, 2016

As Ohiojim said, dry ice is the answer. A chunk or two in the tank is enough to displace all of the flammable gas with CO2, which is not flammable. The second benefit is the vapor is cool, so it keeps temps inside the tank low, which also aids in explosion prevention.

Can't remember who it was Dad talked to years ago that told him this trick, but I do remember the guys repaired railroad tank cars. Dry ice was all those guys ever used and they swore by it for the two reasons listed above.

An additional benefit to dry ice is that when your done, there is no water left in the tank, no residue from any kind of chemical. All that remains is a little bit of C02 vapor.

Charllie in MO · May 11, 2016

It works, but you have to use good sense. Thank you
Charlie

jimg.allentown · May 13, 2016

I don't believe one single word of that story. Too exaggerated and far-fetched.

showcrop · May 13, 2016

(quoted from post at 08:14:52 05/13/16) I don't believe one single word of that story. Too exaggerated and far-fetched.

I can see it as truthful if you change one little detail. Diesel fuel tank last contained gasoline or alcohol or some other flammable liquid instead of diesel. Otherwise very far fetched.

Welding / Cutting a diesel fuel tank

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