*sigh*
I was so pleased with myself to get it up and running. Filled the tank & went out for a pizza. Came back and parked in the garage overnight. When I went I grab something out of the garage the next day, the aroma of gas was strong. Looked under the tank in the back and saw a small puddle of gas and a busted tank strap. Rats.
Thank goodness for the half price sale at 928intl. (My wife is gonna strangle me in any case.)
Another opportunity to learn from a new project! I'll use Dwayne's awesome awesome thread as a starting point.
Blargh.

 

You sure it's the tank and not some plumbing issue?
(I'm back in the plumbing phase right now myself....)

 

There is a thread on pelican about plastic welding the fuel tank. Looks like it worked quite well....I am going to buy the equipment myself as well.

 

PC11 sealed up my spun insert for years without leaking a drop, but may not tolerate flexing...But verify it is the tank , not plumbing - leaks out the gauge head seal when full are not unkown.
jp 83 Euro S AT 54k

 

I saw Dano's thread there. Looked intriguing. When I talked to Tom @ 928intl he mentioned that sometimes the foam on the hanger bracket wears out & rubs a weak spot into the tank. Since my bracket is broken I thought it'd probably be a good idea to snag a good used one while they're cheap. It figures that it would happen with a full tank of gas! Sheesh.
CB

 

Trailered the 94 to the shop today for a similar problem. No puddles under the car but plenty of that nasty gas smell. T

 

yup...I put new foam on my bracket....hope to actually install it soon...Leo's write up was pretty good....be great to master that, as these tanks become more scarce....

 

Check the top of the tank under the plastic cover in the rear deck area. It is where the fuel level sender is and the gasket can leak allowing fuel into the rear area and it can leak down the top of the tank.

 

There seems to be a bunch of stories of cracked gas tanks. 24 gallons of fuel is a lot of weight. I never fill mine above 3/4 full in order to keep the weight on the tank structure down and limit the stress that its subjected to.

 

Don't toss the old tank. We can prolly fix it. I think they are NLA from Porsche.

 

Few places to check before you tank a tank.

Lower strainer/in tank pump. Make sure that 20 year old gasket is not leaking. You will have to pull the tank girdle down to ensure.

Top of tank, fuel level sender gasket. Open the hatch, pull back carpet, pull off cover and make sure there is not a puddle of gas sitting there.

Easy fixes first.

 

Make sure you know where it is leaking from before you start emptying fuel and pulling the tank out. Mine appeared to be leaking about 1/3 of the way up the side of the tank on the filler side but the leak was from the in tank pump gasket. The fuel was moving (don't know scientific term) along the tank bracket through the foam and 25 years of mud then up along the side of the tank before gravity got it and it started to drip.

Got so far along with the removal before I discovered where it was coming from. Cheap part just be careful how much pressure you use getting it back in as you can strip the internal thread from the tank itself.

 

Wicking. Sometimes called 'capillary action'.

 

I found Seans and other posts regarding this matter

Decide to drive the recently acquired 928 yesterday
Took on 10.49 gallons yesterday and after driving 5 miles there was a strong smell of gas, both windows were open and it dissipated quickly

Opened the service door to the garage and there was an overwhelming smell of
fuel

here's why



went right for the ground strap after soaking up the gas and removing the rag

the ground strap sparked, twice...okay really scary
opened the battery door and have the nut off the + side of the battery
but concerned that it will spark too

should I fill a plastic bag with cat litter ( have no sand available) and completely seal off the access to the top of the tank ?
along with a clean dry rag to remove the battery connections and get the battery out ?

I know I'll have to siphon off some gas, it appears I'll need a new gasket
possibly a pump


but for now I just need a safe approach to getting the battery disconnected and out of the car

Safety First

 

Here's why what?? That's the tank-level sender and fuel-return line, not the pump. If it was wet around that fitting (in the well) then that is the non-uncommon leaky gasket for the fuel tank sender.

Step 1: Exhale, then a couple of deep breaths. You didn't blow yourself up disconnecting the ground strap so everything will be OK. Wrap the ground strap in a rag or towel so it cannot accidentally ground, and leave the batery alone-- it is functionally disconnected.

Step 2: You will need to siphon off some gas, to get the level below that fitting. Maybe a single 5-gallon jug, not sure. That should also stop it from leaking (assuming that is the only leak-- which is very likely).

Step 3: Order a new gasket (928-201-327-02), and maybe a new plastic nut (113-201-375-01C), around $20 total from Roger, 928 Int'l, or any Porsche dealer.

Step 4: With parts on hand, remove fuel-return line and electrical connector (carefully pull straight up), remove nut, remove and replace sender with new gasket, fit new nut, torque to spec, replace connector and return line.

(That last bit is easily written, the problem is getting a suitable tool on that nut. Large slip-joint pliers work, sort of, and Porsche makes a special tool which I have one of here-- send me a PM).