Recommend me a fix - rusty fuel filler neck

[garethj]

The Suzuki Baleno has got a rusty fuel filler neck right at the top, it's why there are fumes outside when I've filled up and now I've prodded it with my finger there'll probably be more.

 

I've got a welder but I'm not absolutely comfortable with doing petrol areas, and that nonsense about filling the tank so there's no room for fumes isn't welcome either.  What's my best way to fix this?

 

I could probably:

1. Drop the tank, weld up the filler neck.

2. Would some GRP tape and lashings of resin work?

3. Anything else?

[danthecapriman]

I'd go for lashings of fibre glass and/or resin painted on, or this stuff http://www.tooled-up.com/product/rocol-metal-repair-compound-56g-tube/184487/chemical metal, I've used it on my cars for similar things and we use it on huge power transformers at work! It's good stuff, fluid proof when dried and rock hard.

There's a thinner, runnier similar two part stuff in a little plastic syringe that's good too. http://www.tooled-up.com/product/everbuild-stick-2-rapid-epoxy-metal-25ml/177697/

[dollywobbler]

Do Suzuki stock them? Daihatsu certainly did for the Sirion. In fact, it got replaced under recall, much to my amusement.

[sierraman]

If its a straight section, some jubilee clips, length of pipe over top and a shit load of glass fibre, I'd put something solid under the glass fibre to avoid the stuff falling in the tank.

[Jim Bell]

Plastic milk flaggon split down the middle then stitched into some kind of usable shape with a craft knife and some cable ties?

[garethj]

I've never had much luck with Suzuki Parts Department when I ran an old Whizzkid and a new Cappuccino but I'll give it a go tomorrow.  I've done the search-any-part-breakers thing so we'll see if that brings anything.  Otherwise I'll see if a repair is possible when it's taken out.

[Uncle Jimmy]

The ethanol in petrol knackers fibreglass so I'd go the Shitpeas route.

[Uncle Jimmy]

Radiator hose, especially silicone another possible fix.

[Parky]

Lead piping and solder? Failing that lots of Kurust, an old can jubilee clipped over the top and then smothered with fibreglass resin, paint, bitumen, in fact anything to keep the water out.

[garethj]

Some quality* ideas here, but in the end the answer was a second hand fuel neck from one of those internet breakers.  Car is now fume-free.