PeterV
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 posted on 11/4/11 at 09:26 AM |
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WLR Fuel Tank Woes
It's all gone horribly wrong!
After much sniffing of petrol fumes the source of the wafting high has been discovered. The bend radius of the fuel tank is obviously on the limits
and this one has fractured. Fuel is weeping from the offside rear of the tank approximately 25-45mm in from the corner. The reason it has taken time
to find the problem is because the neoprene, that the tank is mounted on, has been happily getting stoned on the leaking fuel. Finally the glue has
dissolved and the neoprene anti-vibe mat can now be rung out like a wet sponge. With this stuff out of the way the weeping area is much easier to
discovered. It's a gentle weep from what must be a hair line fracture in the aluminium. Some one didn't check the alloy thickness / bend
radius charts or the wrong grade of alloy has been used and its all gone very very wrong.
This is going to create weeks (if not months) of work as the whole body has to be lifted off the car to remove the fuel tank.
So the run to Le Mans 2011 has been CANCELLED. Maybe 2012
Suddenly no one here is holding there breath for 2012 either.
Saturday morning: spent checking torques, trims, tracking and rakes ready for a first drive around the Priory Lodge private roads 
Sunday morning: spent working out how to strip the whole damn car back to it's chassis to remove the fuel tank just to start the work all
over again 
Anyone got any ideas on how to permaently seal up an alloy fuel tank without removal?
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David Jenkins
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| posted on 11/4/11 at 09:36 AM |
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Bad news...
POR-15 make a tank sealant, but you will need to turn the tank over this way and that to get the liquid into all the corners...
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nick205
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| posted on 11/4/11 at 09:47 AM |
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Bummer!
Access may still be the issue for you, but I had to patch my alloy tank after changing the fuel gauge sender. I cut a plate of ally and made a
suitable gasket, then rivetted it over the hole with a bit of fuel resistant sealant for good measure. Admittedly this was on a flat surface and not
an edge, but it should still work if you can make/bend a suitable ally plate. It did leave some swarf in the tank which was a PITA to remove and I
suspect I didn't get it all out, but then the fuel filters are there for a reason. It did however save removing the tank and avoided having to
weld a tank with fuel/fuel vapour in it.
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Davey D
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| posted on 11/4/11 at 09:48 AM |
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How/where is the tank located?
if it sits on a pair of steel rails that are non structural cant you chop them off from underneath, and drop the tank out of the bottom. Then make up
some new brackets so that the chopped out rails can be bolted back in once you lift the tank back up into place?
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PeterV
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| posted on 11/4/11 at 10:05 AM |
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quote:
Originally posted by Davey D
How/where is the tank located?
if it sits on a pair of steel rails that are non structural cant you chop them off from underneath, and drop the tank out of the bottom. Then make up
some new brackets so that the chopped out rails can be bolted back in once you lift the tank back up into place?
Cheers Davey but the angled tank is wider at the top than the bottom so can't that way. Looked doable for a bit coz it only has flat straps
holding it in but can't see a way of squeezin it passed the rest of the chassis.
Thinking along your lines Nick. Maybe I can bond re-enforced angle onto the rear edge of the tank. Anyone tried this
Petropatch
stuff.
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designer
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| posted on 11/4/11 at 10:27 AM |
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If you can see where the crack is, you could apply a coat of resin to patch it, and do a proper repair over the winter.
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scudderfish
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| posted on 11/4/11 at 11:07 AM |
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PETROL FUEL TANK CRACKED LEAKING REPAIR KIT FOR ALFA | eBay UK
Any help?
[Edited on 11/4/11 by scudderfish]
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PeterV
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| posted on 11/4/11 at 11:40 AM |
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quote:
Originally posted by scudderfish
PETROL FUEL TANK CRACKED LEAKING REPAIR KIT FOR ALFA | eBay UK
Any help?
Cheers that looks exactly like the Petropatch add but at double the price. Begining to look like the way to go me thinks.
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MK9R
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| posted on 11/4/11 at 11:50 AM |
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cut the tank up into chunks to remove it from below, and get another made that can be fitted from below. Not a cheap option but mean you have a non
bodged repair, and easier access next time it needs to come out
Cheers Austen
RGB car number 9
www.austengreenway.co.uk
www.automatedtechnologygroup.co.uk
www.trackace.co.uk
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PeterV
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| posted on 11/4/11 at 12:20 PM |
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Neat idea Austen. Think that will be the ultimate answer for next winter when I'm planning further project upgrades anyway. Patch now trash
later.... vengence is mine
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jimgiblett
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| posted on 11/4/11 at 01:40 PM |
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Yep this was my thoughts too.
Bryn at Alifab will make you a tank to your precise dimensions and top quality.
http://allyfab.co.uk/
No connection other than a very satisfied customer.
- Jim
quote:
Originally posted by MK9R
cut the tank up into chunks to remove it from below, and get another made that can be fitted from below. Not a cheap option but mean you have a non
bodged repair, and easier access next time it needs to come out
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nick205
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| posted on 11/4/11 at 02:20 PM |
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Thinking further, how big is the filler neck and/or sender hole - can you get your hands inside to run some sealant along the inside? Or maybe bond a
bit of ally angle inside and out for good measure?
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PeterV
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| posted on 11/4/11 at 02:24 PM |
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quote:
Originally posted by nick205
Thinking further, how big is the filler neck and/or sender hole - can you get your hands inside to run some sealant along the inside? Or maybe bond a
bit of ally angle inside and out for good measure?
Na not big enough, shame cold have sent the kid down to do the job. Prob some law against that no doubt 
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