New gas tank

[dirtydeno]

I have been fighting a bad gas tank on my 270 since i got it. The gas cap had a hole in one of the fire relief plugs for many years before i got it and when it would rain the gas tank would fill with water. The shape of the travco also funnels the water right onto the gas cap. I took the tank to a radiator shop and they said they got 15 pounds of rust out of the tank. They also said they sealed it but now its been about 6 months and my gas is dark brown. Time for a new tank. Ive been searching offerup and craigslist for awhile and i found a gas tank out of a 1984 Fleetwood motorhome. The dimensions are almost identical except its 2 inches deeper and the filler neck is on the side of the tank. I originally was going to relocate the filler neck but after looking at it more its not really a good option so i decided to modify the new tank to match the old.
I added a sending unit to match the travco Ohms. 78-10
I cut off the old filler necks and welded them shut. I pressure tested the tank by screwing in a schrader valve and installing another sending unit.

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I drained what was left in my original tank, washed it out with soapy water and aired it out with my leaf blower.

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I then cut out my old filler neck, the inside of my tank was still full of rust. I could not get a good pic

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I drilled a hole for the neck in my new tank. I made it undersized and then enlarged it with a barrell sander for a tight fit.

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I welded three passes around neck for strength.

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It passed the pressure test so all thats left now is to paint it and install it.

[Arkansas Travco]

Looks good! Can you use the Fleetwood straps or are you going to lengthen the old ones?

[dirtydeno]

Thanks, Ill try a longer bolt and if that will not work ill make new longer straps for one side.

[dirtydeno]

Got the tank painted. Ill put it in this weekend.

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[PrivatePilot]

Nice fab work - looks great!

[gojoe]

I wonder why the coating failed. Going through my tank now. I've cut theach top off and had the inside blasted. That caused some pinholes which I had to weld. Installed new pickup tubing this past weekend. Waiting for por15 tank sealer to arrive then I'll coat and weld a new top on. I hope it holds up I'm gonna have about 20 hrs into it by the time I get it bolted up.

[dirtydeno]

I guessing they didnt actually coat it like they said.