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It's funny that you mention the aluminum tank because I actually considered it. If my tank was in worse condition, I probably would have went that route. I would rather not open the trunk to put gas in so I would have probably tried to figure out a way use the stock filler location.

Hey Ray, any details on that bracket to use the type 3 master cylinder?

Hey this might be off but can you do a repair with a lead stick and torch like thay do for body work? It is designed to run on leaded gas,lol!!! Bill

The problem with lead is that it easily corrodes. It will leak. Yep...almost all of them ran on leaded fuel Ray

So, the best metal is brass or steel for patching for a tank. Did you see that need material I think call Metal Rubbers? The are thinkin for planes and stuff. It is kind grown like nano tec or sugar crystals. It looks kinda like a sun screen film, the sample, but strong! Need some kinda sheet metal that can be trimed and formed and then set some way like epoxy.
Make it so when it forms it creates perforations like in a door panel or a cardboard box for strenght. lol! Thanks for the knowledge!

p.s. So, do they make leaded gas by dropping a few wheel weight in a can of gas, lolololol! LOL, "I put one in my car and it runs better" Info- mercial for lead tables(made from old wheel weights) shipping not included,lol! Like playing with mercury,lol! Just dont do it!

Well, one small hole turned into 3 medium holes. These were in turn cut into 3 large holes and then welded up. The surface rust on the outside is from washing it out one more time. I'm not sure what is coming out, but I don't think it is rust. It comes off in corn flake size chunks about 1/8" thick. It's soft to the touch and does not feel at all metallic, and when it comes out, whats left underneath is clean and clear metal. Is it possible for gas to turn solid? There's a few stubborn spots so I'm going to clean it one more time and that should do it.

I think that may be some of the original paint or epoxy liner. nRay

ecdez wrote:Well, one small hole turned into 3 medium holes. These were in turn cut into 3 large holes and then welded up. The surface rust on the outside is from washing it out one more time. I'm not sure what is coming out, but I don't think it is rust. It comes off in corn flake size chunks about 1/8" thick. It's soft to the touch and does not feel at all metallic, and when it comes out, whats left underneath is clean and clear metal. Is it possible for gas to turn solid? There's a few stubborn spots so I'm going to clean it one more time and that should do it.

Yes old gas turns to LAQUER after it sits for years on end. My 79 Van had this exact same problem, I would dump acid in it and get these wierd funky colored chunks out of it. Dump some acid in it again and use a heavy duty chain (You can get them from Home Depot or Lowes), one that is uncoated, drop it in the tank with the acid and slosh it around. The chain acts like sand paper and will get those chunks out.

The gas that was in there was there for at least 6 years that I know of. Maybe longer. The chain is a good idea. I was going to let the acid sit and then take it to the car wash and pressure wash it out. The sprayer nozzell would fit right down in there and blast that crap right out . I'll probably do the chain thing too. I want this to be the last time.

ecdez wrote:The gas that was in there was there for at least 6 years that I know of. Maybe longer. The chain is a good idea. I was going to let the acid sit and then take it to the car wash and pressure wash it out. The sprayer nozzell would fit right down in there and blast that crap right out . I'll probably do the chain thing too. I want this to be the last time.

I used the chain, but had rust also, so it got the laquer out, just didnt fix the rust.

Luckily, I havn't seen any rust except for the few holes. The inside of the tank looks incredibly clean. At least, where I've cleaned the stuff off looks clean .

ecdez wrote:Luckily, I havn't seen any rust except for the few holes. The inside of the tank looks incredibly clean. At least, where I've cleaned the stuff off looks clean .

Then all you have is Laquer and I bet the chain will fix that problem.

The acid will absolutely disolve the rust. At that point...i would let it sit...and dry and surface rust again. Then put in a quart of phosphoric acid ...like OSPHO...and slosh it around well...and let dry for 24 hours. It turns that surface rust to a permanent black oxide. Then rinse with a very fast evaporating solvent...like a pint of acetone.....and repeat the process. This oxide is a stupendous primer as well. You can then use the gas tank coating of your choice...or none at all, as the oxide is permanent and wil not re-rust. Ray

Yes, I've already picked up a gallon of OSPHO. Just waiting for the opportunity to use it.

Bad news guys.

I was giving the tank one final cleaning this weekend when one whole side basically dissolved away . There is a hole the size of a quarter, and the metal is very thin for about the size of my hand. I think the tank might be a little too far gone for me now. I'm thinking about putting the spun aluminum sausage up in there instead. Maybe one with a center fill hole so I can have the filler hole coming out of a stock hole in the trunk. I guess a side filler hole will work too. I still plan on doing the rabbit steering rack so that will free up some room under there.

Better to find out now, than later on the side of the interstate.

ecdez wrote:Bad news guys.

I was giving the tank one final cleaning this weekend when one whole side basically dissolved away . There is a hole the size of a quarter, and the metal is very thin for about the size of my hand. I think the tank might be a little too far gone for me now. I'm thinking about putting the spun aluminum sausage up in there instead. Maybe one with a center fill hole so I can have the filler hole coming out of a stock hole in the trunk. I guess a side filler hole will work too. I still plan on doing the rabbit steering rack so that will free up some room under there.

Better to find out now, than later on the side of the interstate.

No junkers around that you can salvage a tank from?