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I don't "do" overfills, nor do I intend to, and IMO, don't do it.
I know what can be done from an engineering standpoint and have put in
some thought on a set of personal absolute minimum requirements for
strictly non-sport, technical applications.  The below is my "bare bones
minimum" and carry no guarentee of adequacy or completeness.  Additional
minimum requirements comments are welcomed.  IMO, anyone considering such
activity have at least these elements in place:

 - increased safety provisions during fill, transport, temp/storage, use
 - permanent record for all fills 
 - schedule for destroying the tank after the predetermined # of cycles. 
 - more intensive "quality survielliance" plan & schedule
 - inspection of tank upon each fill (immediate rejection criteria)
 - burst disk design/testing/replacement plan & schedule
 - documented design safety margin under the new operating conditions
 - personal eithic to destroy the tank, never reselling it

Technical calculations should be certified by no less than a licenced
Professional Engineer.  Ditto the dire warnings from this end.

The conclusion I reached was that it very quickly becomes more cost
effective to buy a larger commercially available tank than to re-engineer
the design parameters of an existing tank (Al-80, etc).  Nothing more.


-hh

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