My Mini stinks!

[BruceK]

Have you considered one of these?  It's called a new tank.

https://www.minispares.com/arp1043ms-petrol-tank-saloon-7-5-gallon-1974-up-to-injection

It's twice the price of a por15 fuel tank kit but with none of the hassle.  Potential over billing from DHL should be factored in.

Oh man!    That definitely cracked me up about it being only double the price of the expensive repair kit. Puts things in perspective.

It sure is tempting to consider. The price is really, really good. But it's the shipping cost and the customs fee hassle that is holding me back. At least for now.

I have not ruled it out.

[BruceK]

Possible Plan D.2  Would a small Dremel tool on a stick fit through the sender hole?

Hmmm. I like it. I've got a Dremel flex head cable that would fit the bill...

Possible Plan D.3 A Faucet tool has a flexible self-gripping head to reach up from under a sink to tighten or loosen the nuts around the pipes connected to a faucet set where there is no room to get a wrench in. This particular one telescopes but there are straight-shafted ones too.

Interesting tool. Never knew these existed. The issue remains trying to work with very limited access into the interior of the tank. 

[94touring]

You probably don't have a welder either?  Because I'd be more likely to drill out the pickup tube and install a new one than fight with trying to get that filter off.

[BruceK]

You probably don't have a welder either?  Because I'd be more likely to drill out the pickup tube and install a new one than fight with trying to get that filter off.

Yes, I don't know how to weld, but believe me the thought occurred to me to cut a hole and gain the delicious access. Or as you said, take a reasoned approach and just remove the filler tube and install a new one. 

[BruceK]

Success!  Or at least semi-Success. Or at least far enough to continue.

I have been able to remove the mesh strainer cage from the end of the pick up tube. Part of the filter apparatus still sits on the end of the pick up tube, but there's no screen material on that, so that shouldn't be a problem.  I was also able to use the long needle nose pliers to reposition the pick up tube almost back to where it should be. I plan to lower it a bit after the coating process is completed.

I can see where I poked through the mesh cage with my improvised Roto router, but didn't really do much damage. Also, that mesh (brass?) is super, super fine. Honestly with it being that fine I don't know what purpose the other downstream fuel filters actually accomplish.

[MPlayle]

I seem to recall that originally there were no downstream filters between the tank and carb until much later in production.  The pickup screen would have been the only filter.

I also seem to recall that the most common recommendation is to do as you succeeded in doing - remove the pickup mesh "filter" and leave it off, then put a standard filter in the line somewhere downstream before the carb.  Having the pre-filter on the electric pump and another near the carb covers all bases.

[BruceK]

Okay. I'm starting by flushing the tank with soapy water. Also allows me to test my plugs.

I purchased a pack of different sized vacuum plug bungs for the tank vent and the pickup tube. They are a pretty good fit but I'm securing them with some duct tape to be sure they stay in place. For the sender unit hole I'm using the old sender unit cover. Perfect fit. Almost like it was made for it. 

For the tank neck I found a PVC plumbing cap at Home Depot and I'm using an Edd China-inspired Orange glove as a gasket.

No leaks!

Force drying the tank isn't so easy. I've tried a corded electric leaf blower on a low speed and also a shop vac configured as a blower. Thirty minutes each and there's still some damp patches inside.

[Dan Moffet]

To dry water from it, you could warm the tank from the outside. Hold it over the BBQ or similar cooking appliance. Heat on low.

[MiniDave]

I'm just going to stick the "blow" end of my shop vac in the filler neck and alternately in the sender hole.

Maybe a hair dryer, Bruce?

Sitting it outside in the sun might help too?

[MPlayle]

We are actually experiencing cooler wet weather, so just forced air alone will take much longer.  The hair dryer or heat gun approach to use heated air will help speed up the drying process.

[94touring]

Set it in your oven when your wife isn't looking.