Fuel tank maintenance

[LMP]

I would not have imagined that type of maintenance...but after investigating a fuel leak I endured for some time, here are a few hints.
This tank is subject to a recall (inspection !!) in the USA, but not in Canada.
The tank is easy to remove ...but disconnect all hoses and electrical connectors first from the top access panel, under rear seat. The clamp for filler hose can be cut with a Dremmel tool then replaced, rather than trying to remove .
THe tank has a drain plug ...quite unusual...but a welcome feature that has a flaw : main cause of fuel leak proved to be the corrosion of the fuel tank drain plug seal/washer. This washer is aluminum and contact with steel tank and plug creates electrolysis and unavoidable corrosion of washer .
www.geocities.com/lmp4203/kiasport/washer.jpg
I replaced it with a steel washer and used teflon to seal the plug.

The corrosion was all over the tank
http://www.geocities.com/lmp4203/kia...tankbefore.jpg
Leaving it unattended would have lead to a total disintegration down the line. The metal used is lower grade than tanks I have had on other cars. The padding between the shield and the tank keeps water and is a problem in itself.

After buffing the tank I covered it with 2 coats of spray rubberised asphalt as sold for undercar protection.
http://www.geocities.com/lmp4203/kia...tankafter1.jpg
http://www.geocities.com/lmp4203/kia...tankafter2.jpg
After reinstallation a tiny leak on bottom proved to have been exacerbated . TO be sure, I had not reinstalled the shield specifically in prevision of such an event.
The leak cleared the asphalt coating a few incles around: emptying the tank again allowed to cure the hole with epoxy.
I painted the shield with Tremclad www.geocities.com/lmp4203/kiasport/shield.jpg but did not reinstall the padding .

An array of hoses are sandwitched between the tank and frame
www.geocities.com/lmp4203/kiasport/lines.jpg
and the space was filled with sand and other debris: this is a trap for corrosion and I will ensure to wash that area from time to time. After removing as much rust as possible, I covered it all with spray asphalt.

Bottom line: this tank NEEDS maintenance in the first place, and then needs being washed with water specially in areas where salt is used in winter. Access from the top is easy and it can be washed from there, as well as the space between tank and frame.
Replace the plug seal as soon as possible as the aluminum original will corrode away inevitably.