From the first moment that the car came to our hands, it was obvious that the fuel tank would need some work. It was removed from the car in April 2002 and eventually put back in March 2004.

Loukia busy cleaning the outside.

After cleaning, fuel tank looks in reasonable state.
With the tank out of the car, some basic inside cleaning was carried out with hot water. Then it was supported on two wooden blocks and was filled-up with water to check for leakages. Although the outside surface of the metal looked reasonable, water was coming out from at least 10 different pin-sized holes, all at the bottom side.

A small piece of aluminium was cut out at the top side of the tank, to use the opening for inspection. What was visible of the bottom inside was not encouraging, so it was decided to cut out the bottom side completely.

Bottom inside of fuel tank after cutting out. Not a pretty site!

Middle part of bottom inside, containing the fuel take out round sump. Not serviceable.
Fortunately, the remaining sides of the tank were in good shape.

Upside down view of the tank with bottom side removed.

Inside detail of fill-in tube and breathing pipe.

New aluminium sheet was used to shape the bottom side replacement, as well as a new fuel take-up sump. When everything was ready, the tank was brought to a TIG welding specialist who welded everything together.

Welding accomplished!

New fuel take-up sump welded into place.
The top side inspection hole was also welded back with new metal, while the fuel take-up and float level were restored. In fact, the float level unit was beyond repair, so a new repro. was purchased from a known UK supplier.

Top side inspection hole welded back.

Beware of float level repro units. On the right you see the original resistor coil of the unit, on the left the repro one. Clearly the repro one is badly made, giving jerky and inaccurate readings. I was lucky enough to be able to use the old one on the repro body.
A final water-leakage test was successful. After drying out and a lick of paint the fuel tank is ready to be fitted to the car again.
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