aluminum fuel tank - best welding practice

[H80N]

...I'd be surprised if 90 gallon tanks would be a big problem. I'd still keep the holes in baffles small, maybe only at the bottom. Two per tank wouldn't be a bad thing.

For what it's worth... my 41ft Morgan displaced around 27K pounds... would expect this 45 footer to be in the same neighborhood.... tanks are typically mounted way below the water line ....
Sooooo.... a 650lb tank would probably not make much difference against that mass... I would baffle it well though...

27K divided by 643 = 41.99 or 2.381% of the total displacement... Not a Lot...

[CODE4]

The two tanks are completed. 3/8 NPT couplers welded in, clean out ports, filler necks, and draw tubes.

The owner did the cutting himself with a circular saw, carbide tipped blade, and piece of flat bar as a fence. He did an alright job, I did what I could with the fit up - from what you can see some of the joints were not ideal, but pressure testing both came out fine. Both tanks have two baffles each.

[CODE4]

A few more photos.

[Ltbadd]

The two tanks are completed. 3/8 NPT couplers welded in, clean out ports, filler necks, and draw tubes.

The owner did the cutting himself with a circular saw, carbide tipped blade, and piece of flat bar as a fence. He did an alright job, I did what I could with the fit up - from what you can see some of the joints were not ideal, but pressure testing both came out fine. Both tanks have two baffles each.

Nice job, well done