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Aluminum boat gas tank has a leak. How do I stop it without taking out the whole tank?

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Aluminum boat gas tank has a leak. How do I stop it without taking out the whole tank?

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  1. Think about this for a second. Why did it start leaking? Age? Corrision? Poor seams? Pull the tank and inspect it completely before attempting to make any repair for you may be better off replacing it instead of mending the problem.

    As for the previous answer on welding...this seems like a not so smart thing to do with the tank installed but then again I'm not a welder. You'd have to make absolutely certain the tank is free of all fuel AND all fumes.


  2. J.B. Weld

  3. JB Weld is a two part epoxy putty that you knead together and then stick on the metal / wood; great stuff but I dont think it will adhere well to oily metal.......

    WARNING WARNING WARNING: Gasoline vapors are incredibly explosive! One cup of gas allowed to evaporate......and it will quickly..... has the explosive power of 4 sticks of dynamite!

    Treat a gasoline leak as you would a grenade with the pin pulled! Fix the sucker NOW......and if it's gasoline, probably the only answer is pull the tank and work on the problem from the inside.....AFTER FULLY FULLY FULLY washing it out with lots of soap and water and then clean water, using about 3x as much water as you think you need....

    if it's a pin hole leak or a chaff spot from rubbing, fiberglass and epoxy may work......if it's a factory  welded seem that is failing, the tank is toast.

    Also be aware: if replacing with a fiberglass tank: some 'glass resins are proving to be susceptible to the ethanol in blended fuel  are starting to, well, melt....

  4. do not risk it, take it out, inspect the whole tank , have it repaired , then pressure test it and install it, or find another tank to put in its place.....not worth rigging up, if you do anything the correct way on your boat, make it the fuel tank.

  5. MarineTex will repair it if you can reach the leak. local marine store will have it.

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