Damp fuel spots in boot

[Suchey]

I had a look at the boot lining and its damp with fuel, pulls apart like damp cardboard. I filled the tank up on the weekend to the fullest its been since we have had the EK and the cabin got a very strong smell of fuel. On half a tank the smell isn't as bad. Is there a seal or gasket that can be replaced around the tank? I checked underneath the tank and the fuel line going to the engine and no leaks or moisture apparent there. Thanks in advance for any reply.

[Devilrod]

More likely to be pinholes in the top of the tank than anything else. Cheap and nasty fix is to buy some need-it and place that over the areas or you can buy a tank liner kit like por15 offer and pull the tank and do it properly.

[Harv]

Devilrod is right - most likely rust pinholes. Pretty common, and judging by the surface rust you've got pretty likely. Could

a) the cheap and nasty option. Let the top of the tank dry out, then fill it up at the servo until she'll take no more. Go for a short drive (1/2 a block), then check the boot. Circle all the wet marks with chalk. Get it home, and let it dry out. Use some sandpaper to clean up inside your chalk circles. Buy some Kneadit or Permatex Fuel Tank Repair from Bunnings/SuperCheap/Repco ($20) and apply to the clean(ish) steel. Repeat the fill test until you've got all the holes. If you want to get real fancy, fibreglass over the top of your repaired tank or use the Permatex Fuel Tank Repair kit from Supercheap ($30). This will leave some rusty crap still in the bottom of the tank, and will not stop the tank top continuing to rust.
b) the middle-of-the-range option. Mark your leaks like option a) above and repair with Kneadit. Pull the tank out, flush and coat inside with a POR-15 Fuel Tank Repair Kit (http://www.por15.com/POR-15-Fuel-Tank-R ... _p_62.html) - $90.
c) the "I know a good radiator place and can braze" option. Mark you leaks and take the tank to a radiator mob for a steam out. Braze the leaks. Figure $20-50 for the steamout and maybe $50-100 for the brazing it if you cannot do it yourself.
c) the "I want to keep the car for a long time" option. Replace it with a stainless one from Marty Dean.
M&C Dean Fabrication Pty Ltd
23-27 Gazelle Court Greenbank, Queensland 4124
Phone: 0421060996
You'll get a tank that is now 60L, with no rust issues inside or out. Plan on $900 though.

Cheers,
Harv

[Suchey]

Thanks very much for this. Very good info. Now to work out how to tackle it.

[60Special]

Also check the gasket around the gauge sender unit and put some sealant on the screw threads. Mine was seeping through here on a full tank.
It's a bit easier than a tank repair and worth checking first.
Good luck.
Trevor J.