Jerry Hey wrote:

What wall thickness would be required for 4 x 8 x 12  (roughly one
gallon) aluminum tank with a 20 lb  cap?   An .050 wall 30 gallon
aluminum fuel tank with one baffle will blow up like a balloon with a
couple of lbs of air pressure.  Five lbs,  say good by.     Jerry

Hard to say. Rectangular containers don't do well
when pressurized. 

Best to find something that looks as close to
a sphere as possible. Or make it out of large thin wall tubing.
One gallon is 232 cubic inches. A six inch OD tube
8 inches long is about a gallon.  A five inch tube one foot
long would also be about right. 
  
Paul Lamar
 
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