Tank is not leaking and it's questionable to justify the labor and expense of fabricating a new tank just as a precautionary measure. I have replaced leaking fuel tanks in other hulls and in all those cases there was never a catastrophic failure of the plating or welds themselves, rather a nuisance seep at a cracked weld seam or, in the case of aluminum tanks, electrolysis where a disimilar metal hose fitting was threaded into the tank.
The tank is 1/8" TIG welded stainless. Replacing all hoses while lid is off as well as rehabbing lid by getting rid of 3/4"ply core with Airex. That should take at least 50# of weight off the boat. Also installing flush inspection plates over sending unit and outlet so future inspection or service won't require lifting off center console.
No signs of electrolysis visible on top of the tank or welds. Ran LED borescope in thru the sending unit cutout to inspect inner tank and welds. Only way to inspect tank outer sides and welds concealed by the foam liner would be to do a destructive removal of the tank itself. Once the new sending unit is installed, I'll pressure test at 1.5-2.0 psi.
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