Aluminum fuel tank woes

[TN_Explorer]

Cutting to the chase -- does anyone repair aluminum fuel tanks?

So I fueled the boat up to get ready for a day of fishing. The next day I emptied 20 gallons of gasoline from the bilge -- the implications were so scary - thank the Lord I didn't go out & hit the starter with all that fuel in there.

Anyway, my boat has a 31 gallon tank built in beneath the floor. After removing the helm seat and center console (all wiring and steering/engine linkages) I then took the saw to the floor and after only 8 hours of cleaning out foam, rigging a strap and hoist and a little cussing, I got it out.

I expected the tank to have a lot of pitting and corrosion after 20 years, but it's in pretty good shape. Before I fork over $450 for a replacement tank, does anyone know if the leak (small pit on the side) can be repaired? I will have to be certain the repair is good as once the tank is back in the boat I will never want to open it back up.

 

[BASS MAN]

Look on eBay for one

 

[TN_Explorer]

Thanks, Bassman.

The first place I looked was e-bay. None of the listed tanks will fit. It has to be low profile - like 8-1/2 inches including the fittings. I also contacted Moeller, who built the OEM tank. They make a couple of tanks that will fit, but they are special order, hence the $450 price tag.

That's why I would like to know if the existing tank can be repaired. I also found a very nice aluminum tank that would fit, but the fill and vent connections are in the wrong spot. So right now I either need to find someone that can repair or modify an aluminum tank or spend some dollars I really hadn't planned for.

 

[jake22]

Just a thought....might could talk to a near by parts store such as autozone, napa or something of that sort. Possibly somebody that works there does or knows somebody that welds aluminum. Hope this helps.

 

[lafae7]

Based off of the age of the aluminium, tig welding a pin hole, pit or crack would be easier said than done. I am afraid your only option is a new tank.

P.S. Aluminium will rust just as bad as steel... It just looks different when it does, so getting good contact to make for an air tight weld would be hard even after grinding, chemical treatment, etc...

 

[captain kirk]

Welding on an type of gas tank is highly dangerous even when you think that all the fuel has been removed. DON'T DO IT!!!

 

[porthos33]

What he said^^^^

 

[smughal31]

I would not recommend welding that. $400 is a small price to pay or maybe you could go a different way and buy a regular plastic tank just a thought

 

[Travis v]

There are probably more weak spots inside that you can't see. If you fix the leak that you have now, another spot will probably give out soon. I know $450 is not cheap but it seems like a small price to pay for the piece of mind knowing that you won't have to mess with it again. I've tried to do some cheap repairs before and end up spending more than if I had just done it right the first time. Good luck and be sure to check your fire extinguisher..

 

[dtw2]

i had my tank welded and it can be done by someone who knows what they are doing, i was like you and didnt want to pay the 450 dollars, you want to make sure you soak it in dish washing liquid a fews days before taking it to a welder.

 

[chillerman69]

These is best set of answers to a tech question I've ever seen on this board because everyone is right. Only thing not mentioned was electrolysis, which causes pitting when 2 dissimilar metals are in contact with each other. Since you found the hole, look to see what was going on there, if anything. If it's electrolysis, it might be economical to repair it AND any other spot on the tank that was installed under same conditions. Aluminum does rust (as said above) and doesn't handle stress well. Welding the tank can be dangerous but it's done all the time. $400 for a new tank, isn't bad relative to cost to get tank re-worked, if you have to pay a shop to do it. If you have a friend or friend of a friend, you're set. Must use a high frequency welding machine . Stay away from goop to dob on it but you already know that.

 

[TN_Explorer]

Thanks to all for the responses.

Chillerman, I appreciate the well put response. I have worked around fuel all my life and am well aware of the hazards - and that proper preparation and safety precautions can minimize these hazards. My father successfully soldered automotive gasoline tanks back in the '50s, as I have done on several occasions. We would spend several days cleaning and degassing any fuel container before going near it with heat. If this tank was not aluminum, I would have no concerns repairing it myself.

I was hoping for a professional shop that could repair the tank and pressure test it. I knew the folks on this forum would chime in and I appreciate it. Since there isn't a shop that pops up, my plan is to replace the tank with a new one.

THANKS!!!

 

[digitalcb]

The entire tank is the same age as the bad spot

 

[TN_Explorer]

I believe the bad spot is the result of the way the foam was blown in, which trapped water in a "fold" in the foam along the side of the tank. There is literally no other corrosion on this tank, It looks like new except for the isolated spot on one side of the tank.

 

[digitalcb]

TN_Explorer - 3/9/2016 7:16 PM My father successfully soldered automotive gasoline tanks back in the '50s, as I have done on several occasions. We would spend several days cleaning and degassing any fuel container before going near it with heat. THANKS!!!

</p>

I worked in a shop in the early 60's where they simply ran exhaust fumes into a tank and soldered without any other precautions.</p>

 

[kcsteve]

Google 'gas tank builders near Chattanooga' and several welders and builders pop up.

 

[TN_Explorer]

I have googled until I have googly eyes!!

Here is the final plan:

1. Wait for responses from two separate dealers concerning getting a suitable replacement tank. If they can come through, the boat gets a brand new tank!

2. If I can't locate a suitable replacement tank, I will have this tank cleaned and I will thoroughly inspect it. Using a thickness gauge if I can find someone with one.

3. I contacted a couple of manufacturers, and received a manufacturer's recommendation that I can use Hy-Poxy H-450 Alumbond to patch the tank, as it has very good chemical resistance to gasoline. I would use some aluminum plate to adhere it over the leak. The leak is actually the size of a pencil lead, so a patch a couple of inches square bonded over it should be fine. The tech sheet says Hy-Poxy H-450 can be used to patch an aluminum A/C line and will withstand 650 psi.

By the way, there are aluminum "brazing rods" out there that state they are fine for a fuel tank as long as it is properly prepared and de-gassed: https://www.aluminumrepair.com/aluminum-repair/

I considered going this route, but after consulting epoxy manufacturers, I see no need to apply any heat to the tank. My wife is much happier with this - she still loves me!

I'm off here now to get to work on this. I will make a follow-up post to let you all know how the final project comes together.

Thanks for all the thoughtful posts that have lead to this solution.

 

[richg99]

"I also found a very nice aluminum tank that would fit, but the fill and vent connections are in the wrong spot. So right now I either need to find someone that can repair or modify an aluminum tank or spend some dollars I really hadn't planned for."

Assuming you can find a quality aluminum welder...THIS TANK?......./\....seems like a reasonable solution. You get a new tank; your connections are welded by a professional; no fumes in a new tank;.....Don't know what the price and cost of welding is...but...it might be the answer. richg99

 

[on fish]

If your on facebook, lookup Roosters welding he is in red bank,the boy is very good if your not on Facebook let me know in have a number

 

[wrechin2]

http://www.jpcycles.com/product/352...LS44Ky9R0pg0xQaX5DW_KKsHlkl5AHRZmUaAq0L8P8HAQ