[RichH]

[QUOTE=
I REALLY like the idea of cutting off the top of the tank and lining it with an epoxy to avoid removing the tank. How does one reattach the top of the tank again? How long can the epoxy be expected to last? It is applied by roller? Downsides? Does it ever break down for possible clogging of filters?

Tod[/QUOTE]

Drain the tank, fill with water, cut access holes (with sawzall, etc.) slightly smaller than final access hole(s), clean and epoxy-line tank, go to metal supplier or fabricator and have new access plates made slightly larger than what was cut from tank, ...... measure and locate 'stud hole' in new access cover drill evenly spaced (5/16") holes around the margin of the new cover AND into adhesive backed BUNA strip rubber gasketing. Overlay prepared new cover over access hole cut into tank then using 5/16" drill locate/mark the center of each hole .... then remove the plate and use a drill that is proper size for 1/4"-20 thd tap (sorry, Im traveling and dont have my drilll schedule for a 1/4"-20 tap - buy the tap and drill as a 'set'). drill the old tank access plate margins, then tap the holes and install 1/4"=20 bolts .... so that the bolt head (and star-lock washer) is inside the old tank and the threads are pointing up. Epoxy the bolt heads to seal them to the underside of the top of the tank. Install the new cover over the perfectly aligned holes using a THIN application of silicone RTV gasket cement on the gasket.

You will spend a little time and spend about 1/10th or less of what a new tank costs.

The hardest part of the whole job will be preparing and cleaning the inside of tank for the epoxy - use an aggressive 'garage floor cleaner' to cut the 'crud', etc. and get a small angle grinder (with 60-80 grit sanding discs) to roughen the inside surface after removing the 'gunk'.