Repairing Aluminum Fuel Tanks

For the amount you need for that project try a truck wash.

 

I had tanks on a Freightliner a Classic that corroded under the straps.
I first used a Dremel tool with a carbide burr to ream out all the corrosion until I got down to The aluminum. Several places it went right through.
Then I used course emery cloth to shine up the surfaces around the work I just did.
I bought some epoxy that was designed for aluminum. I found recommendations for it in the boating community. As they have aluminum tanks that leak and had good results.
I slathered the epoxy on , trying to keep it in the region of where the straps will cover it.
Afterwards I never had any leaks and the straps pretty much hid my handy work. Plus the colour of the epoxy was grey so what little you could see didn’t look out of place.

 

I wouldn't put this stuff in a fuel tank if someone gave it to me. Spend the money like SP said and get it strap welded.

I have heard horror stories of POR coming off and gumming up entire fuel systems. Just not worth the risk to me. Plus you would probably need 20 cans of the stuff anyhow.

 

I couldn't count off the top of my head how many I have had done! Isolator between tank and saddles always seems to swirm out on KW's and running dump trucks that don't get washed much at all adds to it. The guy I have do it ain't cheap, but I will check an invoice. He just done a three strap T800 this week. He is kind of welder that could weld a di** on a snowman! Plus, his TIG welds look factory.

 

Jb weld. You'll never look at it again.

 

I’ve had them banded, I bought new and I’ve used JB Weld. Banding or JB take your pick. New tanks lasted a year. Garbage.

ditch the rubber isolators and use old securement straps instead, check them weekly and take fairings off to wash

 

Just wanted to say I appreciate the thought process of this thread. I have a little leak in old fuel tank... so now I have a path to a solution!!

 

Warning on using the securement straps, especially if they are behind a faring and out of sight. If the edge of it freys, this seems impossible, but the loose end will blow and wear a hole in the tank, I have fixed more than one of them.

The haul road is terrible with mud and gravel, all tanks eventually (and it doesn't take that long) I had mine strapped like mentioned before, except I used 1/8 by 6 and welded all the way around. My son did it I helped, so all it cost me was the aluminum, permanent fix. I then polished the strap and put bedliner on the rest of the tank. This was several years ago and I bet my son did 15 or more oo's trucks that way over the next year or two, I do not have a clue.
For the acid to clean them, I just use alumnabrite, picked up at any truck parts store.