Home › Forum › Ask A Member › Mercury KD-4 Cast Aluminum gas tank seam leak › Reply To: Mercury KD-4 Cast Aluminum gas tank seam leak
Louis, Seal-All is on my list of “good as any”. Just bothers me that there’s
not a product that says something more convincing than “resistant to fuel”.
The gasket I took out was about .019 thick….. closer to 1/64″ I believe,
but after much lapping of the halves today, I can still see a gap on the outside
seam when I hold the two halves together. I didn’t bolt them together dry yet to see
how it looks. I did quit a bit more lapping after the photos were taken.
The old window pane I used was 1/8″ thick, laying on my workbench that’s
made from a solid oak door. It all seemed pretty flat, but perhaps not perfect.
I glued 4 sheets of sand paper on each side of the glass. 60 grit on one side, 100
on the other. I first duct tapped the window to the work bench to hold it steady, but
ended up screwing a board along each side of the mirror. It didn’t wiggle around then.
The original machining on the tank half seams was rather crude, with
lots of machining grooves, but perhaps that helped hold that 70 year old “mystery” sealer in place.
The Karropak I have on hand is only 9″ wide, so I’ll check out your part number.
Thanks again!
Prepare to be boarded!


