I think my fuel tank is leaking... DO NOT USE THIS UNSAFE REPAIR METHOD

[kcassells]

There are tank mfg's in your area I'm sure that will quote a new aluminum tank. They provide a blank tank shape, you fill in the #'s and they follow back up with a quote. You can also make your own sketch and em other local fabricators for quotes. Good luck and yes that tank has served you well. Save and send the drawing you posted it's perfect to use.

 

[tpenfield]

Yes, that tank is far gone . . .

Google some aluminum welders/marine tank manufacturers in your area. The cost of the tank will be $10-12 per gallon of capacity. I got a 90 gallon tank from a local shop about 5 years ago . . . $980.00

 

[fixingstill]

Working on it. It is true that a lot of the local welders are not interested but I have not given up. At the same time, I am still looking for the right plastic tank. Looks like I have to give up keeping the existing hoses and I might have to go smaller in capacity. If anyone knows a plastic tank (dimension in post above) that fits, please let me know.

 

[kcassells]

Moeller is probably your only source for plastic tanks.

 

[Mikeopsycho]

Just remember installing a plastic tank is different than installing aluminum. Plastic needs room around it for expansion, and the coffin needs to be vented to the atmosphere, as gas fumes/odor will permeate through the plastic.

 

[fixingstill]

Guys, I sincerely thank you for your suggestions and I tried really hard to find a replacement. However, after spending countless hrs online and one day driving around, I gave up. There is no ready-made plastic tank that will fit even if I don't mind modifying the hose connections. My coffin is 23.5" wide and my tank is 23". The closest is Moeller FT4037 but it is 24". Locally, there is one boat salvage yard 40 miles from me and they made me drive over there and the tank has no leak but a lot of corrosion pits. They want $400 which I doubt it will last a few years. For making a new one, it was like I had to beg these local welders to take the job. Most don't touch aluminum. One wanted $1200, another wanted $1450 and 3 weeks time. Online, I found one for $600 but they stopped replying my question of shipping to CA. Another one wants $1250 + shipping of $250.

Read this:
http://www.boatsurveyor.com/aluminum-fuel-tanks/
It says "Tanks failed in recreational boats from three to 27 years old," I don't see the point of putting in a new aluminum tank if it ends up leaking sooner or later. At this moment, the decision I have made is to fix this one and MAKE IT WATERPROOF.
Read this:
http://www.sailfeed.com/2012/07/one-...um-fuel-tanks/

I am using Marine Tex to patch up the corrosion pits and then I will use Travaco Gluvit Epoxy Waterproof Sealer + fiberglass cloth to seal up the tank.

https://www.amazon.com/gp/product/B001446LMW
https://www.amazon.com/gp/product/B001446LH2

Here is the step one I am doing (patching up after sanding and cleaning):

I will post more when I am done.

Again, thanks for all the suggestions.

 

[kcassells]

I looked at probably a million how too's for a few years while working on my boat because I have the time. That whole set up is nuttin but a BIG KABOOM. But as I learned...It's your boat and you can do what you want.
Sincerely,
Boom Boom

 

[fixingstill]

The National Technical Information Service did a fairly comprehensive study in conjunction with the U.S.C.G. on aluminum fuel tanks causes of failures....
This article is really interesting:
http://www.boatsurveyor.com/aluminum-fuel-tanks/

 

[Mikeopsycho]

I'm thinking that because your tank is easy to get to for inspections and/or future replacement, I'd do something like what you plan to do, repair it and keep an eye on it. I'd recommend that you go a step further and make the tank coffin hatch even more easily accessible and open-able, so you can have a look-see and a sniff test every time you use the boat.
Are the products you've selected gasoline proof?
Good luck.

 

[fixingstill]

Yes, I will make an access door to it. Yes, Marine Tex and Travaco Gluvit Epoxy Waterproof Sealer are made for marine use. I think the whole boat industry is moving away from aluminum tanks because that are so problematic. Why put in another one when I can fix this one and make it more reliable by water proofing it.

 

[tpenfield]

you really need to get a new tank . . . It is going to cost you a bit, but safety is paramount with boating fuel systems.. What gallon capacity is your current tank?


take a look at the 40 gallon belly tank (#59182) on this link http://www.rdsaluminum.com/marine-stock-below.html

 

[fixingstill]

Your suggestions were appreciated however I had to go the feasible route.
This project is now done.

Thanks, guys.

 

[Mikeopsycho]

It ain't pretty, but hopefully it holds up for you. Did you air test it?

 

[Benny67]

I had an old Regal that I pulled the tank and repaired it with aluminium brazing rods. It was real easy and cheap.

I drained all the gas and let it bake in the sun for a day or so with all the fittings off. Then let it sit another day with a small fan blowing in the hole for the sending unit.

When I brazed the holes I purged the tank with C02 from my homebrew kit to assure it wouldn?t blow up. If you don't have a co2 tank, you can just pump exhaust from your car into the tank...it will do the same thing.

The entire process too a bit of time but only cost me $15 in rods from Harbor freight.

I also pressure tested it with a 4" magnehelic guage that measured in H20" You do not want to pump more than 1/2 PSI into a tank like that.

The tank never gave me another problem.

 

[Benny67]

I didn't see the last of these posts before mine went up.

Dude,

Don't put that time bomb back in your boat...and if you do, please disclose this repair to your passengers and maybe fly some sort of warning flag when you are out on the water to warn others of the potential disaster that may arise by boating close by.

Man...it's just not worth it...please think again about this before going any further.

 

[fixingstill]

Aluminum corrodes. That is why so many tanks are leaking and the boat industry is switching to plastic tanks. (Do buy a new boat without it!) Mine corroded and no way I will spend $1500 to put in another aluminum tank waiting to be corroded down the road. Plastic tank is the first choice but if I have to put an aluminum tank back in, I would waterproof seal it (and fiberglass would not hurt). If I do that, I would just repair this old tank.

Marin-Tex and Travaco Gluvit Epoxy Waterproof Sealer are made just for this purpose. Look it up.

I think a new aluminum tank would have a bigger chance of giving me a BIG KABOOM than what this tank would.

Yes, I did a 3 PSI test and it held up.

 

[chevymaher]

I am cleaning my tank out now, It says tested to 30 lbs on the tag

 

[funk6294]

Been there done what you are trying to do and ultimately ended up getting a new tank made after the old tank failed and filled the coffin with fuel. Basically ended up doing the job twice. The ethanol in the fuel will eat the resin. I ended up going to a local fab company and they made me a new one. For a 125 gallon tank it set me back about $1000. We upped the the thickness, and added tabs to hold the tank in. It was a large number, but in the end I wish I would have just replaced it right off the bat for all of the additional headaches it caused.

 

[kcassells]

Denile ain't just a river. Good luck and seriously you should let antone who rides on your boat sign off on a waiver.

 

[Benny67]

Man, I would not bet my life on marine tex...I've used it a few times and yes, it's a fine product but I wouldn't use it in this aplication.

Gas WILL break down THE BOND between the aluminum and epoxy. It WILL leak...maybe not today...but it will in a short amount of time.

You really appear to be "betting your life" that it wont.

If you just used the aluminum brazing rods and took the time to do it correctly you would have a permanant and safe repair

Anyway, I don't want to be a jerk....I wish you well and safe boating.

Please reconsider before possibly hurting yourself or someone else.