[bestgenman]

Noticed a wet spot on the pad at home and then at the track, the grass was oily, and several other places we've stopped for a day or so.  Removed the stainless cover and      .  Sure enough the tank has rusted enough that fuel is coming out, bummer!  Decided against JB weld or any other patch.  Started removing      which wasn't difficult at all.  It's a little tight on the studs spot welded that hold the parallelogram door mechanism.  (that's my name for the door mechanism) , i had to cut a little off of them for clearance. Once out, I noticed the barrier between the battery compartment was rusted at the bottom.  Finished up the side walls with rust encapsulator and prepared to add a piece to the rusted out area.      .  After the applications had dried, added a piece of HDPE to replaced the original plywood      .  Once the tank was out, I took some measurements, removed the suction tubes, and was impressed by the size      .  The suction tubes extend nearly to the bottom (both Aqua-Hot & generator) however the main engine suction extends into the sump/sediment tank which is about 3 gallons.  
   

Commissioned a friend to build a new tank from aluminum, pictures follow
                   

Coated the bottom with a substance similar to bed liner and zinc chromate to the rest. added the suction fittings and fuel gauge.  I made the tank 3/4" shorter than the original to aid in installing (the fill neck was a tight fit upon removal).  However I discovered the tanK gauge sender was too tall so, I had to turn out a spacer.
       

Reinstalling was easy, it was the door that took all day.  the tank capacity is 268 gallons now.  I figured when the generator runs out of fuel, you've 30 gallons left.  there is a low fuel float switch that activates about the same time.

Quite a project but fun anyway.  Without labor, cost was about $4,500.