Mercury KD-4 Cast Aluminum gas tank seam leak

[Buccaneer]

Bill, after lapping what seemed like forever yesterday, with a bad cold, wearing a dust
mask, I would have gladly paid $40 to have the tank halves lapped, but alas,
I’m kind of “out in the sticks”.

Prepare to be boarded!

[green-thumbs]

The means and methods I use are those that met the needs and circumstances as well as my personal preferences.
Far be it from me to discourage more innovative and less labor intensive ways to achieve the same end result.
For those who might be interested
Elmer’s Spray Adhesive
220 or 180 wet or dry paper
pack of single edge razor blades.
water
layout dye or felt marker
medicine cabinet door mirror
feeler gauge
Seal All
Felpro Karropak gasket stock
Time and Effort

I would not suggest a piece of plate glass due to possible
personal injury.
Louis

[Buccaneer]

green-thumbs wrote:

The means and methods I use are those that met the needs and circumstances as well as my personal preferences.
Far be it from me to discourage more innovative and less labor intensive ways to achieve the same end result.
For those who might be interested
Elmer’s Spray Adhesive
220 or 180 wet or dry paper
pack of single edge razor blades.
water
layout dye or felt marker
medicine cabinet door mirror
feeler gauge
Seal All
Felpro Karropak gasket stock
Time and Effort

I would not suggest a piece of plate glass due to possible
personal injury.
Louis

Louis, thanks for all the good tips. I felt confident the 1/8″ window pane
wasn’t going to break laying flat on my heavy oak door workbench.
I screwed boards along each side to hold the glass in place,
and duct taped the front edge so I would not get cut…… I dislike blood,
especially my own. :-O

Prepare to be boarded!

[Author]

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