Some have been interested in how I refurbished my tank so I started a second one to show how it was done.
First, grind the weld down to just where you see cracks opening. At this point I take a small, sharp chisel and wedge the seams open. I do this to maintain as much steel as possible on the seam for easier welding.
The back bracket welds have to be cut and the bracket bent back enough to allow access to the seam under it for grinding and welding. The bracket is bent back and welded after this is done.
In this case, the port was lead soldered in place which was removed. The port is always a good area to reweld since it can be a potential leak area. The weld appears to be on the inside only, but a fillet weld on the outside would double its leak resistance, but change appearance from the original.
Overall, this is not a very difficult or expensive process and can return a rusty, dented old fuel tank to like new condition. I am considering trying a similar procedure on oil tanks as well.
Once apart dents and interior rust are easier to remove as well as an interior weld of the port, after which the above process is reversed with a good TIG weld around the mating seams. I also add 1/8 npt cross over ports to connect unuseable fuel from one side of the tank to the other.
