Question about replacement gas tank.

(To skip my long windedness you can jump directly to the four numbered questions at the bottom. Thanks!)

We have, as some of you may recall, a 1958 Chris Craft that we've restored and been using. This year we have taken the engine out to have it rebuilt. Good thing we did. The exhaust manifold was about rusted through and the inside of the engine is also all rusted through such that the water jacket passages were not cooling her properly. (Though the temperature gauge was getting plenty of cooling, so it looked ok by the gauge.)

Anyway - aside from the engine, we are thinking of replacing the fuel tank this year. The tank is steel and is rusting inside. We see the rust in our fuel filter. Quite a lot of it. ~ I don't mind changing the filter from time to time, but don't want a gas tank leak.

So -- the current tank is a cylinder shape. Approx 50 gallons with INSIDE dimensions of about 15.75" diameter and 57.5" long. (Outside is a little bigger with the thickness of the steel and on each end there is a "lip" overhanging.)

As a first step I called the company RDS that does custom tanks for West Marine. They said they "won't" make cylindrical tanks. ~ The man I spoke with was not sure if that's only because they don't have the equipment/ability to make cylindrical tanks or if it's some safety issue.

So, four questions:

#1: Is there any reason to avoid a cylindrical tank as a replacement?

#2: Anyone know who much make such a tank?

#3: We're thinking replace the steel tank with aluminum to cut down on weight. Any reason NOT to do that?

#4: If we can't find someone to build the tank we want is there any process or coating that can be done to salvage our current tank? (Current tank is rusting inside, but not leaking)

Thanks, Gary

The space we have for the tank is limited. The cylindrical shape works well there. But it would have to be very close to the same diameter & length. Otherwise it wouldn't fit or else we'd loose capacity.

So, can they custom make those polyethylene tanks to my needs and/or do you think they'd be available in the size we need?

Thanks.

Also contact Coastline Equipment in Bellingham, WA. they make most of the aluminum fuel tanks for the northwet boat manufacturers.