Cardboard to a Custom Fuel Tank — Professional Design Process

From Cardboard to a Custom Fuel Tank — Professional Design Process In this video, we walk through the step-by-step process of designing a custom fuel tank, starting with an old-school but highly effective technique: cardboard mock-ups. This is a full walkthrough, showing how professional fabricators and restorers design one-off fuel tanks with accuracy and confidence before any metal is cut. Using simple materials like cardboard, tape, and markers allows us to refine shape, capacity, mounting points, clearances, and serviceability — eliminating guesswork later in the build. If you’re designing your own custom fuel tank, restoring a classic car, or planning a high-end custom build, this video explains why cardboard mock-ups are still used in professional automotive fabrication, even alongside modern CAD tools. In this episode, we cover: • Why cardboard is used in professional fuel tank design • How to mock up a custom fuel tank step by step • Checking fitment, clearances, and packaging • Designing for real-world fabrication and welding • Preparing a design for CAD and metal construction This video is designed as a practical, start-to-finish walkthrough that you can follow to design your own custom fuel tank at home or in a professional workshop. 👉 In the next episode 2, we take this cardboard design into CAD modelling, laser cutting, and TIG welding to turn it into a real, finished metal fuel tank. custom fuel tank design, cardboard mock up, fuel tank fabrication, automotive fabrication walkthrough, step by step fuel tank design, custom car fuel system, restoration fabrication, professional fabrication techniques, custom car build, fuel tank mockup, how to design a fuel tank ________________________________________ ________________________________________