Reply To: Mercury KD-4 Cast Aluminum gas tank seam leak

[green-thumbs]

I used 220 wet or dry glued to mirror and LOTS of water…
and flushing grit and metal off frequently.
The paper has to be replaced several times as it tears
Elmers spray adhesive to glue paper down and single
edge razor blade to scrape off glue and paper
Twin tanks are wider than paper, does not seem to make a
difference so long as each side if overlaps edge while
the other on paper.
I put first tank on surface plate and measured gaps with feeler
gauge marking area and gap on a piece of foam board
with outline of tank. Layout dye on tank mating surfaces
proved to be a good idea. The high spots and low spots showed
clearly as work progressed. I found that coarser grit than
220 removed metal faster and gave a decent finish.
Most important is to flush frequently as the wet or dry
loads up and stops cutting otherwise.
First tank came out well, subsequent tanks improved
technique. I left out a few details in step by step
to avoid cluttering up with details.

Louis