I am so pissed right now. I was getting ready to put my fuel tank back in since the mods and other stuff I did to the tanks. Anyway, I put it on the bench and made sure it was secure. I stepped away from the bench to get something and all I heard was crash, the fuel tank rolled and then fell to the floor. It landed right on the filler neck, making it out of round...i.e. flat spot. I banged it back to round, I thought cool I am all set. Right before I went to mount it in the boat, I put some solvent in it for a final cleaning. All of a sudden I see the solvent coming out near one end of the tank and not the filler neck as I was shaking and draining the tank. I looked again where the solvent was coming out and there is a 9 inch long crack where the end cap is welded to the tank. Shit, now I have to go through the whole welding process of this tank again. I know I can fix it but I wanted to be ready for this Sunday (supposed to be 92 here). I have to now rinse it out with the aluma-brite cleaner (phosphuric acid) , prep the crack and purge the tank with Argon so I can weld it. This sets me back. 
So today I just mounted the other tank and got the vent line stuff all set up.
T.J.

I have Toms (JBP) boat here in Morgan Hill that has two round SS tanks, don't know if he would mind you borrowing one. I also have the stock side tanks from a 1986 Bahner (square) if this helps at all

PM me if you think these can help.

Ok the tank is fixed. Sorry no pics. I did not have the camera with me. I first washed the tank out with the aluma-brite stuff. Cleaned the crack, fired up the Dynasty 300DX machine to 80 amps. The tanks are only .065 or so. I also backpurged the tank with pure argon for a while before I began to weld. As I got a puddle going the crack was migrating to the left and right like a bitch. It ended up being about a 11" long weld. Hooked up my pressure test jig and put 5 psi inside the tank. Shit, still a leak where I cannot even see a crack. Welded the bastard up some more. Re-pressure check and spray with soapy water, no leaks.
Good to go. Got the tank in the boat with the new vent lines and all -12AN fittings and lines going to the water/filter seperator. Just a few more things tol do on my list before I get it in the water again.
  T.J.

make sure the rotors turning......

Crap TJ, I'm sorry to see this thread but knowing your craftsmanship, I'm betting we all think it's better now than it was even before your whoops.

Kinda reminds me of a bazillion years ago when I was a teenager, had a bare small block setting on the work table at home and set a head on the locating dowels without putting any bolts in, turned my head to grab something and that sumbitch popped off the pins and fell from the 4' landing right on my big toe........Note to the gang here, cast iron heads and toes don't mix.  I smashed the shit out of it and didnt even crack the head.....

Sincerely........Fat-Toe Johnny

Been there done that, small block head to right big toe. Big toe lost. Worst thing is that it ended up getting nail fungus and lost the whole nail. Finally had to have it permanantly removed. Toe looks all effed up now lol.
No Toe Nail Sam