Build for 100 gallon capacity aluminum fuel tank

[flyingfrizzle]

Here are the baffles being installed and welded in. Normally baffles get tabs bent on them around 1" at the edges to be welded vs welding them in direct. Since I used 3/16" thick material I was able to weld them in direct as tee joints vs lap welds on the bent tabs. I did have to add tabs to the center short baffle on one side though. I could weld 3 out of the four tabs both sides but the last one got covered when the longer baffle goes in so it had to be plug welded to the tab from the outside. You will noticed the short pieces with tabs then the larger baffle with holes drilled in it. The baffle gets plug welded to the smaller baffle threw the holes. And yes, it is tight crawling in a 12" wide box half way in it to weld these in. The outer two were not as bad but the center one was tough to access.