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**HappyMdRSailor** · 31-03-2016, 04:59

Mini Update -

Decided to go with a sealing repair simply because 99% of the tank is in perfect condition... Just a few small spots where water pooled on the bottom for a while... If there were corrosion, fatigue, leaks etc... anywhere I would go the "pull and replace route"

PLUS... I have about 20 hrs into making the 4 inspection plates!

Both the POR and KBS coatings are a no go...
POR-15 Fuel Tank Repair Kit
https://www.kbs-coatings.com/tank-sealers.html

Talking to both, came to the same conclusion... Any bare tank to coating interface was likely to fail... ALSO - I've used one of these before or similar, and it worked great... But the coating as judged by the cured leftover was less flexible than I deem adequate here...

After perusing all of the aircraft tank sealers and websites, I settled on this:
Flamemaster CS3204 A-2 Gray Integral Fuel Tank Sealant - A+B Quart Kit at SkyGeek.com

BTW... Skygeek had the best prices, AND they were the only people to answer the phone when called... When a 5-8 day delay popped up on the confirmation, a quick phone call resulted in changing it to a "drop ship", as easy as you please... No delay, 3 days total...

Tank is clean and dry now... going to scrub religiously with acetone... Then use this metal prep etching for the bottom:
Amazon.com: POR-15 40204 Metal Prep - 1 quart: Automotive

Wash, scrub, dry, repeat acetone scrub, and coat with sealer...

I don't have any delusions that my qty of 2 quarts is going to self level perfectly and give me a uniform 1/8" on the bottom... so I'll either:
A-Brush the complete bottom once, twice or thrice
or likely this-
B- Make tape barriers around the pitted regions to build thickness there, and then coat the bottom a few times...

Will let you know how it goes!