fuel tank failure on E29

I finally got the nerve up to cut the lowest tip off the gas tank on RUMKIN my E29. I used a hacksaw to cut the welds and a bone saw to finish the cuts across the plate aluminum. It was necessary to remove about four inches of the deepest part to remove the tank from the boat.

I am including pictures to let you know what the inside of the tank can look like and to let you know the dangers. In the pictures you will see the hole and the kitty litter looking stuff that was in the tank. There was a post about an A4 carb filled with gray goop, I also have had that problem, I think this is the stuff.
Not only did I have a hole in the tank but the filler hose that connects the tank to the deck plate had a ½” cut at the top of the tank neck that would leak if laid over hard to port or if the tank was topped off.

The top portion of the tank needs cleaning but is in good shape, I am thinking of having a plate welded over the hole and reusing the tank.
Yes-No-Maybe?

If you have a 25 year old gas burner check the tank and hoses often

material question

In the photos the tank looks like aluminum. If so, I have read many times that this is not a good choice for gasoline, although it is best for diesel fuel.
If aluminum, a local fabricator told me that it is extremely difficult to clean up the surface of old aluminum enough to make a good weld bond to it. Others say that patching aluminum worked fine for them.

Any welders here?

Loren in PDX

what will $.02 buy here.

It is aluminum and I talked to a shop today that said they could safely weld a plate over the hole I creted. I also talked to a second shop that said it would weld with no problem.
What do I get for my $.02 from the gang?

Tank.

I had a original steel tank in my boat when I got it. It had a very large hole in the lowest end of my tank. It was nasty. Well I just went through all the welding senerios and decided on a new underdeck Tempo plastic tank. They were on sale at Bass Pro and I got a twelve gallon tank for $79.00. It was rectangle so I had to do some adjustments but I made it a shelf in the berth and it has been a dream. I ran all new tubing to the engine and the deck fill. I think the only thing I hated was paying $9.00 a foot for the fill tubing at west marine.


Just my $0.05 worth(inflation price rise)

I think I'd go ahead and weld it up. Given the shape of the tank and spaces available, I think you'll find it the most efficient way to get x gallons of fuel stored on board. You also won't have a non-original fitting tank somehow used against you at the point you sell her (I know it seems like you'll have her forever, but...)

There, my .02 and nothing more or less

Randy

For your .02 worth I plan to toast you with a beer.

John

Beer

John some people wil use any excuse to have a beer. I think I will have one with you.