fuel tank woes

[almostbroke]

I have a rusty "black iron" fuel tank that needs replacing. It can''t be removed in one piece because of the interior. That means the replacement can''t go in either in one piece. I have a few options: 1)Replace it with two smaller tanks(that would make fuel routing fun!) 2)Cut off the top and put a bladder inside(my least favorite) 3)Fiberglass a new tank in place(is this advisable?) 4)Give up one of my stainless water tanks and get out of the slip sooner 5)Find a good deal on more jerry jugs 6)Actually learn how to sail everywhere instead of motoring all the time....
Any advice would be appreciated, especially on the subject of a fiberglass tank.
Rusty Bottom

[RichH]

Consider:

Cut top off of present tank. Sandblast interior of present tank to ''white'' metal. Put in liner of epoxy and cloth, ditto to the cut-off top. Apply ''flanges'' with embedded stainless nuts to tank cut out margin. Put tank (with new epoxy liner back together using epoxy mush to fill in the overlaping and newly installed flanges, draw up bolts to previously installed embedded nuts just before the epoxy ''cures'' ..... or go to www.westsystem.com and look for the project index for: metal tank ''lining and repair".

Benefits: uses the old tank as a ''form'' for the new tank (liner).
Disadvantages: when the two ''sections'' (tank and tank top are joined back together the contact area must be perfect or the ''seal'' will be incorrect - permitting fuel to get between the old tank metal and the new fiberglass liner.

[sailnaway]

As much of a bummer as it may be the facts are that to do it right you need to take the interior apart and replace the tank with an amuminum or stainless tank. I have the same problem only with the tow rails and the bolts are buried in glass behind interior wood which would mean taking the whole boat apart to get to them.I think you would do best with a fuel bladder they are tough and if you clean the hole the old tank is in up you might even get a little more space out of it. this all sounds good but no one can see your tank location but you, Supply the members with the (manufacturer and type boat you have) if you post that info maybe someone will have some better ideas.