*EDIT: In the summer of 2014, I replaced this tank with an eBay purchase. It did leak just enough to keep the bottom "damp." But, considering I go into Canada and back into the USA, I was afraid the border agents might look under and see the patch on the tank and end with a search. So, it was time to replace it.
Okay, although I've not posted much info lately, work on the project is slowly moving along.
Here are photos of the fuel tank salvage project. This tank is in fairly good shape on the outside, especially the outside top which typically has rust issues. However, as stated in the previous post, it does have a hole in the bottom due to internal rust.
The plan is to cut out the center sump section for inspection and hopefully repair. The challenge will be to put it back with no leak results.
All views are from the bottom with the front of the tank at the top of the photos. The rust you can see where the holding straps are located on the bottom of the tank, is on the coating, not a problem.
Notice the the circle "marking" the cut line...also see the drilled hole for starting the jig-saw. The rust hole is just below and to the left.
Ready for the jig-saw ........... yes, it's safe....no gasoline fumes at all! The piece of wood only allows the jig-saw blade to go so deep. (I still cut the suction line....see if you can see it in one of the photos.
Here, the dremel was used to get past one of four baffles.
This photo depicts the cut almost completed. The X's mark the location of the four baffles. I changed jig-saw blades to finish those off.
This photo shows the sump out and facing up........ wow, lots of rust! Notice the hole to the left of the strainer. It has part of the other strainer broke off in it. You cannot see the pick-up hole for the big line on the left.
At the work bench, I heat and pry loose the two part sump. It is sealed with some sort of epoxy as well as four spot welds (dremel took care of those) You will be able to see the location of the spot welds in one of the photos below. See the white plastice piece to the left of the strainer. Well, that broke off the return strainer.
This photo shows the sump after I separated it into two pieces. Top right is the very bottom of the sump. You can see the four spot welds and some of the sealant. To the left is the top part of the sump with the intake strainer in the center. The hole to the left of the strainer is where the return strainer was located. The return strainer is still in the tank to the right there.
This photo is similar to the above, however the center section of the sump is flipped. In the flipped position, you can see the center hole where fuel enters the bottom of the sump after going thru the strainer. The hole to the left is for the pick-up line that takes fuel to the engine and the hole on the right is where the return fuel strainer is connected (remember, I broke it).
I plan to eliminate one or both of the strainers.......... if they ever get "plugged" with black algae, the tank will have to be removed and cleaned. (Remember, this tank will be holding diesel fuel.)
So, I may try to come up with a means to bolt (screws) the sump back on!......scratching head right now! Ideas welcome. I've considered using JB Weld. JB Weld is resistant to diesel fuel.....not sure about Biodiesel! I believe a round piece of aluminum can be temporarily put over the hole while treating the tank. Then, that cover can be modified and attached to the refurbushed sump. At that point, I will attach (screws with sealant or JB Weld) sump to the tank..... presto!
As for the rust, that will be addressed with etching acid, rinse with water, rinse with acetone to remove the water and then coated.