Aluminum gas tank dent repair

[Buccaneer]

Trying to get the tank on the Johnson A-80 somewhat more presentable
than it was. I decided on the "air pressure and heat" method instead
of cutting the tank in half and re-welding, as my aluminum welding
equipment consist of some $10 aluminum rods and gas / oxygen torch,
and my skill with such "suck", lol.
Anyway, I’ve progressed thus far (as shown in the photos), and decided
to quit before disaster struck.
The heat from the torch and air pressure did most of the work, and a little
help from a hammer.
Just wondering what I should do to make it better yet?
Sound I continue with the heat and air pressure, or
just start block sanding and "tapping" with the hammer and little
here and there?

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Attachments:

Prepare to be boarded!

[dave-bernard]

Good job so far.

[RICHARD A. WHITE]

If memory serves, increase your air pressure to 9 psi, not 8, not 10, but 9 psi, then use heat and tap around the dents and they should get better…. AOMCI President Jay Walls did a show on this at our North Webster Indiana meet one year….fascinating…

http://www.richardsoutboardtools.com
classicomctools@gmail.com

[kees]

.
is your torch not too big?
It looks like a cutting burner, rather dangerous IMO
I prefer a propane solder burner for more control of the heat
.

[Buccaneer]

Kees, yes, it was a cutting torch. I use propane instead
of acetylene, and had it adjusted to a "lazy" flame,
so as not too hot. Otherwise, all I have use is a
too small brazing tip.
Perhaps I should see if the tank still mounts on the
power head before I to any finishing work on the
tank.
The top of the tank was pretty decent as far as dents.
The vise kept the flat top from "bulging out" from the
air pressure. Not sure the magic number as far as
air pressure. All I know is that too much might be bad. 😮
I would think air pressure would be a variable depending
on the design and shape of the tank.
Thanks!

Prepare to be boarded!

[RICHARD A. WHITE]

Jay Walls insisted on the 9 psi, not 8, not 10 but 9 psi…

http://www.richardsoutboardtools.com
classicomctools@gmail.com

[kees]

quote Buccaneer:

I would think air pressure would be a variable depending
on the design and shape of the tank.
Thanks!

of course !
thickness of the aluminum will vary by tank or brand
and the corrosion areas must keep you sharp too.
.

[squierka39]

You’ve done good so far, but might I suggest you place a want ad for another tank. The A-70, 75 and 80 should all be the same. I’ll bet you can find one with minor dents ready for polish. Run this till you find one.

[Steve A W]

Wow!
I didn’t know there was anything like boat demo derbies. 😯
LOL
That poor motor had a hard life.

Steve A W

Member of the MOB chapter.
I live in Northwest Indiana

[david-bartlett]

quote Richard A. White:

Jay Walls insisted on the 9 psi, not 8, not 10 but 9 psi…

I would agree. 10 pounds and too much heat caused a “blowout” on my Bendix tank. I was fortunate that I was able to hide my repair under the decal.

Use propane and a light touch with the hammer.

[Author]

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