Holes in Tank

Kant · 01-18-2005, 03:31 PM

Hi,

My nice Porsche 944 from 1983 that I like soooo much is getting me into many troubles... actually the previous owner is!

This stupid guy digged some holes in the filler pipe and IN the tank, in order to fix some sound system!! I removed the sound system, fix it in a nice way, brought my car to the mechanic in order to get an estimate of the cost ... and it seems that they will have to drop the tank, clean it, fix it, put it back... all of this for $1200 ! I already spent $1500 for a new clutch, so I am a little bit afraid of spending again some more money... specially (as you may have read it on another topic) as I feel like I am gonna have to change suspensions and flywheel one day or the other ...

Any suggestions ?

Should I get rid of this car ? But I like it, that's the pb ...

Should I get a new tank? Would that be cheaper than cleaning and fixing the current one ?

Does anybody knows somebody around San Jose, CA , who could help me doing this, or do it for a cheaper price ?

Thanks all,

livewirevoodoo · livewirevoodoo's Garage

assuming you mean the gas tank... i've heard rumors of people mounting audio equiment into the rear hatch flooring into the gas tank.. IMO, gas vapors and stereo electronics are not a fun mix.

For $1200, I'd want a new gas tank, not the old one fixed. Not sure of their availability tho, quick checks on pelican and ebay turn up nothing.. So right now, 1500 for clutch plus 1200 for fuel tank = $2,700 into the car.. thats prolly more than 1/2 its worth.

you could always:
1) fix it..
2) sell it
3) part it
4) take out alot of insurance and total it

seriously tho.. how long have you had it? i'm guessing not too long if your just finding out about the gas tank... so weigh the cost vs. the emotional attachment vs. cost of a new one and what you might get for it by selling it (although i dunno who would want it with holes in the gas tank) or part it (might actually make more $ than the car is worth whole, but it could turn into a drawn out pain in the ass... though you could keep the good spare parts for the next nice 944 you buy)

good luck

ernestedward · 01-18-2005, 05:14 PM

It cost me around 900 bucks to have my tank dropped, patched, and replaced. Keep in mind that most of it is labor, and at 80-90 bucks/hour, you can EASILY hit 1000 for that job. They basically have to take apart the whole rear of the car...

livewirevoodoo · livewirevoodoo's Garage

the trans has to be dropped, no? i wasnt sure.. also wasnt sure if it makes a difference on pre/post 85.5s....

ernestedward · 01-18-2005, 06:42 PM

Yeah, trans, most of the rear suspension too I think..there's a lot in the way. I doubt its different on early and late.

AFJuvat · 01-18-2005, 06:56 PM

The transmission does need to be dropped, the rear suspension can remain in place.

$1200 seems a little high. somewhere around $1000 or so seems about right.

AFJuvat

seaboltman · 01-18-2005, 10:17 PM

if i were you, i would do this

Have them cut a hole in the floor of the trunk space
Patch the hole from the top
weld piece back onto trunk floor

Its a win win the way I look at it. You dont pay for HOURS upon HOURS of labor as this would proabably take 2 hours at the most. And you get to keep your 944 that you seem to love.

As for the trunk floor, thats why theres a mat, it wouldn't cause any cosmetic harm what so ever.

Mike(dat's me) · 01-19-2005, 07:36 AM

Use a cutting torch right above the gas tank? I'll admit I don't know much about that, but it sounds like a weeny roast waiting to happen.

Actually.... it kinda sounds like something I would do...

SoCal Driver · SoCal Driver's Garage

Not a cutting torch. The panel cutting fork in an impact gun would work. Then find a 944 in the salvage yard you can cut a slightly larger piece out of to cover the hole.

Actually if you can find another 944 in the junk yard take the gas tank out of it, have it repaired by a shop that does gas tanks and put the repaired one into your car. Don't cut any holes.

In most cases of fuel leaks when the gas tank is filled full it's the cross over the top vent hose that leaks. This is usually at the base of the filler where it makes a sharp 45 degree bend. You can patch this with a short section of copper tubing bent at the same angle with out removing the tank!

NOTE: Early 944 gas tanks are not the same as the later 944 gas tanks.

seaboltman · 01-19-2005, 07:56 AM

... the obvious percautions of draining the tank would of course, occure. After that, wait for a few hours with the gas cap off, hose removed and the trunk lid open, and fumes would be gone as well.

Mike(dat's me) · 01-19-2005, 08:22 AM

Quote:

Originally posted by SoCal Driver
Not a cutting torch. The panel cutting fork in an impact gun would work.

A who? I think I have more to learn than I knew. Go figure.

SoCal Driver · SoCal Driver's Garage

Called sheet metal rippers:

Mike(dat's me) · 01-19-2005, 11:45 AM

Ok, that is the first one I have ever seen.

You know, it's odd, when I was teenager my dad would kick me out of the garage when he was working on the cars and tell me I wasn't mechanically inclined.

He came to me to hook up all the electronics though! hehe

I'm learning to turn a wrench later in life than most. I hope someone is deep down here in the south to bail me out of the trouble I will eventually cause myself.

Kant · 01-19-2005, 04:15 PM

Thanks guys for your help!!

I appreciate very much !

I am gonna ask my mechanic about doing what you said (taking awayone part on the top of the tank) and also i am gonna try to find a gas tank in a yard ...

If you have other suggestions, let me know

I will tell you the end of the story!

btw, i am gonna read again all those posts to make sure i got it right

)

Kant · 01-19-2005, 04:21 PM

To be clear about where the leak comes from : there are two holes (small) digged on the top of the tank. The leak doesn't not come from the filler pipe actually.

So, finally I shouldn't cut the top of the tank ? OR maybe you mean : if I can find another tank, then I don't cut. If I can't I can still cut, it's better than nothing.

Anyway, if I find a tank, then it's gonna cost me the same $1200 (0r $1000 whatever), because it's gonna take the same 10 hours or just a little bit less, as it's a pain in the ass to remvoe the tank on 944 ...

So... the only "reasonnable" solution is patching the top ?

Thx guys,

SoCal Driver · SoCal Driver's Garage

It's not a difficult task to drop the transmission. Need a few "special" tools such as the 12 point allen to take the drive shafts off.

Once the trans is out of the way you disconnect the fuel pump on the engine side and use a jumper on the #2 to #3 fuse to run the pump and drain the tank into some containers. Could do it at the engine too.

Remove the hoses between the fuel tank and the filler tube assembly then the two straps to drop the tank.

You can use expanding plugs to seal the two holes on the top of the tank if they are small enough. Get the newer vent hose for the tank not the cloth covered stuff.

Could do a tank swap in about four hours no problem.

Kant · 01-19-2005, 04:58 PM

4 hours ... I don't understand why my mechanic wants $1200 then ;-). Even if he told me his rate is $90/h ... hum maybe I should find another one

Anyway, if not swaping tanks, there is no way to "fill" the holes without cutting a bigger one ? I ask this just to know a little bit more before talking to the next mechanic

Thanks,

Quentin
Porsche 944 - 1983

Kant · 01-19-2005, 05:05 PM

One more question, please : how much should be a reasonnable price for a gas tank ? I mean not new of course

Just not to be fooled again

Thanks,

fast924S · fast924S's Garage

Just ditch the old gas tank and drop a fuel cell in the back

SoCal Driver · SoCal Driver's Garage

Because the mechanic is quoting the flat rate and my not have done this a few times himself. A trans can be out in about 30 minutes when you know what needs to be done and have done it a few times before.

Where do you live?