Aluminium fuel tank repair

[nick.hopper]

Noticed a strong smell of petrol in my garage and a few drips of fuel on the floor.  On closer inspection fuel pipes and gaskets were all dry / okay but the tank was damp around the bottom rear right hand corner. I isolated all the fuel lines and wiped the tank clean. Left it overnight but tank was definitely leaking the following morning.

Going to drain and remove the tank for a closer inspection.

Does anyone know a repairer in the Kent area?

 

[SM25T]

You could ask Boss Racing in Longfield or Sevens & Classics at Brands .... sure they'll know.

[Pendennis]

Metal weld paste will sort it, easy fix

[nick.hopper]

Thanks Pendennis. I've seen metal weld paste on the market. How reliable is it?

[A10ROX]

Mine doing the same ...

diagnosed as worn baffles ... so tank replacement advised

[Pendennis]

Very reliable, repaired mine in two places two years ago no leaks ever re materialised

[Mark w]

My experience is that if it's old and leaking its best to bite the bullet and replace it .

holes are like busses , fix one and another arrives shortly after .

[nick.hopper]

Thanks for the posts guys.  No stock in Caterham until end of March for a new tank so I'll give the metal weld paste a go. I've read loads of good reports on it so it's worth a try. At least it's good practice if I do need to replace it later on :) 

[JwBye20]

Ppg 1440b2 fuel tank sealant would be best if you could get hold of some 

[BlackSeven]

JB Weld works perfectly for this job but as ever, surface prep is important; I cleaned up with a small stainless brush on a Dremel and then cleaned with panel wipe. 

As others have said though, once you start to get leaks, others can follow. I fixed two leaks around 3 years ago using the above method and they are still perfect but I have recently noticed a third leak in a completely different area. My tank is almost 30 years old and I am guessing the aluminium gets brittle with age and vibration and these tiny cracks then form. 

If this is the first leak a repair will certainly buy you come time.

 

[C7GCS]

My tank is 'venting' on my '94 JPE. Intending to get Boss Racing to inspect and replace with new STD tank in July pre- MOT. The JPE cars had a special design "low centre of gravity" alloy saddle tank that wraps around the rear diff and drive shafts, so will see if the original can be repaired too.

[alan c]

I have the same "saddle tank" in my car and had mine repaired by Arch. They made them originally so they know where all the baffles are etc. It should also have foam in it as well.

[Jim 123]

I got an email from Frost's re POR15 Fuel Tank Sealer, any use?

http://www.frost.co.uk/faq-3-step-por15-tank-repair-seal-tank-guide?utm_source=2017_04_21_POR15Tank_FAQ&utm_campaign=2017_04_21_POR15Tank_FAQ&utm_medium=email

[C7GCS]

Thanks for the pointers - I will look into these.  I think its got to that age where I need to get it out, cleaned out and checked over by Arch.  

Due to its dimensions I take it the Saddle tank is a case of diff and drive shafts off to drop the tank out?  I've note really got as far as looking at it yet, just know I need to do something with it; as its the only thing letting the car down at the moment (and noone wants to put their car away with a super u/l fuel in it only to find it all evaporated away when you next come to run it up).

thanks 

[alan c]

Yes you have to take the suspension apart and then drop the tank out. I was very busy when my tank was causing problems and it was removed for me by some very good friends.

While it is out to get the leak dealt with I suggest you get Arch to check the mounts for the fuel pump and the fuel guage sender to make sure both are flat and true - that's why mine had to come out twice! Hence very good friends.

if you want to see what it looks like out of the car send me your email address I have some pictures somewhere. There are, I believe, at least two versions of this tank. One is circa 44L capacity and there is a larger one the top of which is very close to the top of the boot.