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Leaking gas tank - the odyssey continues 140-160 1972

posted by  Lord Volvo on  Mon Aug 13 19:13 CST 2012
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last visit: Sat Oct 4 15:55 CST 2014
[RELATED]

I posted a bit ago about how my 142 has developed a leak at the gas tank's drain bung due to (I think) pressure inside the tank due to a missing fuel expansion tank. This leak is now far worse and occurs even when pressure in the tank is released.

I've researched ways to patch a hole or crack in gas tanks but didn't come up with a sure-fire cure. Speaking of cures, some possibilities include an epoxy and POR-15 patch putty, which is supposed to be resistant to fuel. But nothing but some epoxy and patch work keeping up to 15 gallons of gas inside a pressurized tank doesn't instill a lot of confidence.

POR-15 does offer a fuel tank repair liquid, but I'm not sure if it would be enough especially if the bung connection is worn beyond repair.

Welding is another option, but how would a professional welder do this without blowing himself up?

I've sourced a new gas tank but at over $300 plus international shipping, it ain't gonna be cheap.

Can you ship a used gas tank if it's ripe with fumes?

Any advice?
--
Mike F - 1984 244 DL - 317,000 miles
Original engine, transmission, drive train, starter
Undergoing reconstructive surgery with POR-15

1972 142 S - The Yellow Brick - 135,000 miles
All stock except for Weber Carb. B20B engine. M40






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