TIG-welded auxiliary fuel tank repair that's built to last

A cracked auxiliary fuel tank isn't something you patch and hope for the best. A leak or structural failure in a fuel system is a real problem - one that can sideline your operation fast. That's exactly why this job needed more than a quick fix.

Here's what we were working with: a diamond plate aluminum auxiliary fuel tank that had developed a crack and needed serious attention. We didn't just seal it up and call it done. We repaired the crack, added a reinforcing plate around the threaded fitting opening to beef up that high-stress area, and TIG welded everything clean and tight.

TIG welding is the right call for aluminum work like this. It gives us precise heat control, which matters a lot on aluminum - too much heat and you're warping the material or creating weak spots. The result is a strong, clean bead that holds up under real-world conditions. No shortcuts, no guesswork.

The reinforcing plate we added does more than just cover the repair area. It distributes stress across a wider surface around the fitting, which is exactly where tanks tend to fail over time. Think of it as building in a margin of safety that wasn't there before.

Whether it's a boat fuel tank, a truck auxiliary tank, or any aluminum fuel system component, this is the kind of work that keeps equipment running and keeps problems from coming back. We take aluminum repair and modification seriously because the alternative - a second failure - isn't acceptable.