Leaking fuel tank

#1 by Mikexx , Fri Feb 23, 2018 10:25 am

Discovered a slow drip of fuel under the truck. I was expecting a leak around the seam but it seems its coming from a pin-hole a few inches above.

Also discovered how expensive these tanks are, Milners are £430 or so. The last tank I got was for a Fiat and that was nearer £130, so surprised at the cost.

Since the hole is accessible without removing the tank, I was considering Fertan and some two pack paint as a temporary measure.

I'm reluctant to buy a second hand one as these will be as old as mine (2005) and likely fail in double quick time in the same way.

Is there a cheaper supply?


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RE: Leaking fuel tank

#2 by 123hotchef , Fri Feb 23, 2018 10:30 am

not see any cheaper to be honest but I have not looked that deeply, If mine were to leak I think I would drop it weld it then paint it with some epoxy


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RE: Leaking fuel tank

#3 by Mikexx , Fri Feb 23, 2018 10:50 am

Quote: 123hotchef wrote in post #2
not see any cheaper to be honest but I have not looked that deeply, If mine were to leak I think I would drop it weld it then paint it with some epoxy


Thanks, that would need fully emptying and left in the open to vent any fuel for along while.

This seems to be a pin-hole, which begs the question how many more are itching to spring another leak?

Do tanks only rust on the outside? I thought tanls had a habit of rusting on the inside, above the fuel level, from condensation? The pin-hole is above 1/2 way implying as much rust inside as outside?


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RE: Leaking fuel tank

#4 by Major Malfunction , Fri Feb 23, 2018 10:56 am

I put a new one on about 3 yrs ago the old one was leaking around the seam when it was dropped the old tank was pretty well fooked. Second hand tanks like you say are rot boxes, it maybe cheaper to get a new tank fabricated. The price hasn't changed much at milners.


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RE: Leaking fuel tank

#5 by Major Malfunction , Fri Feb 23, 2018 10:57 am

Your engine sump will be next, although they are more repairable


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RE: Leaking fuel tank

#6 by ronniecabers , Fri Feb 23, 2018 1:11 pm

@Alan G has a tank , not sure the state that it is in though. The tanks will rot at the top because they collect all the mud and shite up there, so it sits on the tank longer working its evil magic......


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RE: Leaking fuel tank

#7 by 123hotchef , Fri Feb 23, 2018 1:23 pm

it probably is cheaper to get a new tank made from scratch. @alex200 what would a ali tank cost to make


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RE: Leaking fuel tank

#8 by alex200 , Sun Feb 25, 2018 10:40 pm

If anyone has an old knackered tank they could send me I could have a measure up and sort a quote out.


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RE: Leaking fuel tank

#9 by mike-b- , Mon Feb 26, 2018 8:47 pm

Buzzed mine with a wire brush and paint last time it was off. Seem to suffer at the rear and top worst!


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RE: Leaking fuel tank

#10 by Mikexx , Mon May 21, 2018 12:19 pm

I've seen some ebay listings where the compatibility list suggests the same tank fits both old pre 2006 and post 2006 vehicles.

Is this the case and I can buy a new(er) 2006+ body fuel tank? Or are the listings simply wrong!?


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RE: Leaking fuel tank

#11 by krutly , Mon May 21, 2018 4:28 pm

pretty sure the listings must be wrong bud as the new and old ones are a different shape


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RE: Leaking fuel tank

#12 by Mallinman , Mon May 21, 2018 9:22 pm

I Tig welded any ally wagon tank the other day. Didn’t empty it all out. Just run the tank till it’s on fumes and then weld with the cap off. Extinguisher near you. Or if real concerned then run empty and put water in. Then drain out after. Diesel doesn’t ignite that bad.


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RE: Leaking fuel tank

#13 by Mallinman , Mon May 21, 2018 9:23 pm

I bet alex could knock some new ones up cheap for people if he had enough interest. @alex200


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RE: Leaking fuel tank

#14 by 123hotchef , Tue May 22, 2018 12:06 am

yeh come on @alex200 some stailess tanks would work well


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RE: Leaking fuel tank

#15 by alex200 , Tue May 22, 2018 4:43 pm

If someone has an old tank they'd be willing to let me have for a bit I don't think ally or stainless tanks would be a problem to be honest. Laser cut and folded and I'll tig it together. I've sent in a complete set of pram bash plates in for cad profiling so a tank should be easy. If not I'll do it myself.


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RE: Leaking fuel tank

#16 by AD , Tue May 22, 2018 5:30 pm

Quote: 123hotchef wrote in post #14
yeh come on @alex200 some stailess tanks would work well

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RE: Leaking fuel tank

#17 by 123hotchef , Tue May 22, 2018 5:35 pm

who has a old leaking tank then @Major Malfunction did u bin urs


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RE: Leaking fuel tank

#18 by Major Malfunction , Tue May 22, 2018 7:32 pm

@123hotchef it's a cheap Euro part now it was about 4yrs ago when mine went in the bin


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RE: Leaking fuel tank

#19 by Mikexx , Sun Aug 18, 2019 11:42 pm

Quote: alex200 wrote in post #15
If someone has an old tank they'd be willing to let me have for a bit I don't think ally or stainless tanks would be a problem to be honest. Laser cut and folded and I'll tig it together. I've sent in a complete set of pram bash plates in for cad profiling so a tank should be easy. If not I'll do it myself.


A long time has passed but eventually replaced the tank for another that doesn't leak. I spent a long time only filling half way!

I'm pretty sure the leak is associated with a loose baffle and possible issues with a broken spot weld.

If any fabricator wants one to borrow a tank then I have this one. It still have the various ancillaries fitted.

I'm in Worcester/Bromsgrove.


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