Aluminum Gas Tank Repair

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  • March 23, 2015 at 4:35 pm #12619
    Buccaneer
    Participant

      US Member - 1 Year (includes $3 online payment fee)

      Tubs, I think you talked me into plan "D"! Like you say, I think the
      back of the tank is fairly well reinforced, and the ends are a small
      enough area that they may be okay. Will have to play with some
      regulators to see if I can maintain a low psi. Thanks!

      Prepare to be boarded!

      March 23, 2015 at 5:14 pm #12622
      RICHARD A. WHITE
      Participant

        Lifetime Member

        Try 9 psi, this comes from tech session with Jay Walls doing the demonstration. He said and I quote, "Not 8 psi, not 10 psi…9 psi is the number", LOL

        http://www.richardsoutboardtools.com
        classicomctools@gmail.com

        March 23, 2015 at 9:15 pm #12635
        Buccaneer
        Participant

          US Member - 1 Year (includes $3 online payment fee)

          Glad the magic number isn’t 8.5, and I hope my regulator
          isn’t made in China! After today, the Neptune is starting
          to look like an outboard again. Started cutting some 2×6"
          boards for the gas tank cage, so perhaps I’ll put some air
          to the tank tomorrow.

          Prepare to be boarded!

          March 23, 2015 at 9:23 pm #12636
          chris-p
          Participant

            At work, I have a "pin gun", which "welds" whatever gauge pins, in whatever length I need onto metal.

            I wonder, if I weld the pin on the dent, then use a slide hammer to pull the dent out, the grind off the pin and buff out?

            Havent tried it yet but may on an old tank I don’t mind ruining.

            March 24, 2015 at 12:12 am #12647
            Buccaneer
            Participant

              US Member - 1 Year (includes $3 online payment fee)

              Went back out to the garage after supper, and started putting together
              a gas tank bomb shelter for the dent removal operation.
              I used 3-1/2 torx screws, but will put a bar clamp on each end for good luck.
              Think this will suffice?

              Gas tank bomb shelter?
              http://www.grayhitandmiss.com/Outboards/tank1.jpg
              http://www.grayhitandmiss.com/Outboards/tank2.jpg
              http://www.grayhitandmiss.com/Outboards/tank3.jpg
              http://www.grayhitandmiss.com/Outboards/tank4.jpg
              http://www.grayhitandmiss.com/Outboards/tank5.jpg
              http://www.grayhitandmiss.com/Outboards/tank6.jpg
              http://www.grayhitandmiss.com/Outboards/tank7.jpg
              http://www.grayhitandmiss.com/Outboards/tank8.jpg

              Neptune Progress ….
              http://www.grayhitandmiss.com/Outboards … ch2015.jpg

              Prepare to be boarded!

              March 24, 2015 at 12:18 am #12649
              RICHARD A. WHITE
              Participant

                Lifetime Member

                One note, rinse the inside of the tank with soapy water, or at least water many times, if using heat you want to make absolutely sure there is NO leftovers in there.

                http://www.richardsoutboardtools.com
                classicomctools@gmail.com

                March 24, 2015 at 2:12 am #12659
                Buccaneer
                Participant

                  US Member - 1 Year (includes $3 online payment fee)

                  It’s been cleaned inside with Pinesol and a handful of wood screws, shaken, not stirred.
                  Hopefully Pinesol isn’t flameable!
                  I always like to first take the cap off a cleaned tank, and shoot the torch flame
                  inside the tank quick to make sure there’s no flameable vapors.

                  Prepare to be boarded!

                  March 24, 2015 at 11:09 am #12674
                  jerry-ahrens
                  Participant

                    US Member - 1 Year (includes $3 online payment fee)

                    😀 Tubs is correct, it’s very easy to bulge out an aluminum tank if your not carefull. I did that to a PO15 tank years ago. It took all the dents out, but now the tank looks pregnant and also holds a lot more gas!

                    March 24, 2015 at 11:56 am #12676
                    kees
                    Participant

                      International Member - 2 Years
                      quote Buccaneer:

                      looks solid enough
                      and….can’t wait to see the results
                      post more photo’s please

                      March 24, 2015 at 12:08 pm #12677
                      gjonz
                      Participant

                        I use the method above. Air inside..least outside…tapping with a rawhide mallet as needed and on bad dents I will alternate heat with a cold source…IE; snow, ice, or dry ice. This allows the metal to get hot…then hitting it with dry ice it will contract and move back toward its original shape due to the temp difference.

                        I’ve done this on "neck cushion type tanks" like you are doing now, steel Firestone teardrop tanks, and even a few big Johnson SD tanks that are in fact pressure tanks made of very heavy aluminum.

                        The air pressure may need to be more for some types of tanks, but start with what Tubs is suggesting.

                        It takes time, and patience, but it will get there!

                        Greg

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