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 Hawk trunk floor gas tank mount rust-out repair
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Golden Hawk Member

732 Posts

Posted - 11/16/2009 :  12:26:35 AM  Show Profile  Email Poster  Reply with Quote
This summer the gas tank in my 1963 Hawk dropped down on the right side due to the mount bracket having pulled out of the trunk floor because of the mounting surface rusting through. This was not because of road salt corroding it (it's a CA car), but because the trunk lid leaks water beyond the weatherstripping. The weatherstripping is like new, but I find water standing on the trunk floor after I wash the car and this standing water is what rusted the recessed area of the floor that the gas tank mounts to. So check this area of your floor so that you don't unexpectedly have your gas tank fall out like mine did.
This shows the large hole where a mount should be bolted to. This is the rusty chunk that fell out and remained attached to the gas tank bracket. This is the hole after I cut the rusted steel away with a cutting wheel on a small hand grinder. The four black markings are to help me locate where the center of the bolt hole will be. This is the patch I began making out of 18 GA steel with a pocket to replicate the original piece. I used a flat head body hammer to force the metal down into the recession that I milled into a piece of firewood. This is the piece of firewood that I took and marked out dimensions that I measured from the original piece. I set the router to mill 1/2" deep and followed my markings.
I followed up with a utility knife to bevel the edge to replicate the inside form of the original piece. border="0"> After drilling a clearance hole for a 3/8" bolt, I bolted the tank to the patch so that the weight of the nearly full gas tank would hold down the patch tight to the trunk floor so that I could weld it. I used the black markings to locate the bracket before welding.
Removed bolt, ground down the weld, wire brushed it, and then primed and painted it. After the paint cured, I installed a new bolt and put a rubber spacer between the bottom side of the patch and the gas tank bracket and tightened it. I need to get a spray can of undercoating yet and undercoat the bottom side of the repaired area. I would be happy to loan my piece of firewood to anybody, but I need to burn it to heat my house & garage.

Brent's rootbeer racer.
MN iron does your body good.

Edited by - Milaca on 11/16/2009 12:37:52 AM

Commander Member

9754 Posts

Posted - 11/16/2009 :  05:12:37 AM  Show Profile  Email Poster  Reply with Quote
Excellent repair! I would never have tackled that process, or even thought of it! Of course, part of it is that I have zero ability with wood My likely course would have been to set about finding a donor piece from somebody's parts car.

Great thinking and great repair!

Robert (Bob) Andrews- on the IoMT (Island of Misfit Toys)
Parish, central NY 13131


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Commander Member

1252 Posts

Posted - 11/16/2009 :  06:18:08 AM  Show Profile  Email Poster  Reply with Quote
Nice work. Remove your gasket and lay some linerless rubber splicing tape in the channel to raise the gasket up a bit higher in the channel. At least 1 to 2 times for whatever desired thickness you require for shimming. Keeps the water out of my trunk. Stuff is available in a couple different widths from electrical supply stores. You may have to trim it depending on what width is available to you. Mine was 2 inch but it comes in either 3/4 or 1 inch also. Made by Scotch. the 3M people.{SCOTCH 130C Linerless Rubber Splicing Tape} Glue your gasket over top of this stuff. jimmijim

Stude Junkie+++++++Do it right the f$$$$ Time. Never mind. Just do it right. When youre done your done. You'll know it.
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