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DIY Welding Project: Expansion Tank [Guide]

Andy Weyenberg

Welding Project:  Expansion Tank

Welding Project: Expansion Tank

Leaking axle vent hose? Fix those worn seals or small seeps with this expansion recovery tank project.

Expansion Tank Project Plans

Tools and Materials:

 


  • Miller® Multimatic® 220 AC/DC multiprocess welder
  • 6063 or 6061 alloy aluminum round tubing (1-5/8" x 1/8") (5" long)
  • 1/4" aluminum plate or flat stock for the end caps
  • Sander/grinder
  • Drill bits (5/16", 7/16", 33/64", 9/16" x 18" fine tap and 1/4" pipe tap)
  • 3/32" 4043 or 4943 filler metal
  • Rivet nut setter
  • Brass filter
  • 1-1/2" x 4" x 1/8" aluminum plate or flat stock for the mounting bracket
  • Hole saw
  • Hand drill
  • Vise  
  • 5/16" rivet nuts (2)
  • 1/2" wrench 

 

WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER’S MANUAL.

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Posted Feb 2, 2024

Andy Weyenberg

Andy Weyenberg

Andy Weyenberg began welding at his father’s business a few years before joining the Army. After going to school for Electro-Mechanical, he started working for Miller Electric Mfg. LLC as a technical service rep and training instructor. Andy has built and raced stock cars since he was a teenager — and now builds high-performance street vehicles.